CA2078949A1 - Composite composition having high transparency and process for producing same - Google Patents
Composite composition having high transparency and process for producing sameInfo
- Publication number
- CA2078949A1 CA2078949A1 CA002078949A CA2078949A CA2078949A1 CA 2078949 A1 CA2078949 A1 CA 2078949A1 CA 002078949 A CA002078949 A CA 002078949A CA 2078949 A CA2078949 A CA 2078949A CA 2078949 A1 CA2078949 A1 CA 2078949A1
- Authority
- CA
- Canada
- Prior art keywords
- parts
- weight
- radical
- carbon atoms
- mixed solution
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 74
- 239000002131 composite material Substances 0.000 title claims abstract description 45
- 238000000034 method Methods 0.000 title claims description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 166
- -1 vinyl compound Chemical class 0.000 claims abstract description 95
- 239000008119 colloidal silica Substances 0.000 claims abstract description 59
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 52
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 42
- 150000001875 compounds Chemical class 0.000 claims abstract description 27
- 238000006068 polycondensation reaction Methods 0.000 claims abstract description 16
- 238000006460 hydrolysis reaction Methods 0.000 claims abstract description 15
- 230000007062 hydrolysis Effects 0.000 claims abstract description 14
- 239000006185 dispersion Substances 0.000 claims abstract description 10
- 230000000379 polymerizing effect Effects 0.000 claims abstract description 6
- 239000011259 mixed solution Substances 0.000 claims description 84
- 229910000077 silane Inorganic materials 0.000 claims description 50
- 239000007787 solid Substances 0.000 claims description 40
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 36
- 239000002904 solvent Substances 0.000 claims description 29
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 28
- 125000004432 carbon atom Chemical group C* 0.000 claims description 25
- 239000004215 Carbon black (E152) Substances 0.000 claims description 22
- 229930195733 hydrocarbon Natural products 0.000 claims description 22
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 15
- 150000002148 esters Chemical class 0.000 claims description 14
- 239000000243 solution Substances 0.000 claims description 14
- 229920000642 polymer Polymers 0.000 claims description 9
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- SNVLJLYUUXKWOJ-UHFFFAOYSA-N methylidenecarbene Chemical compound C=[C] SNVLJLYUUXKWOJ-UHFFFAOYSA-N 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 6
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 5
- 125000000217 alkyl group Chemical group 0.000 claims description 3
- 229910052681 coesite Inorganic materials 0.000 claims description 3
- 229910052906 cristobalite Inorganic materials 0.000 claims description 3
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 claims description 3
- 235000012239 silicon dioxide Nutrition 0.000 claims description 3
- 229910052682 stishovite Inorganic materials 0.000 claims description 3
- 229910052905 tridymite Inorganic materials 0.000 claims description 3
- 238000010526 radical polymerization reaction Methods 0.000 claims 3
- JHPBZFOKBAGZBL-UHFFFAOYSA-N (3-hydroxy-2,2,4-trimethylpentyl) 2-methylprop-2-enoate Chemical compound CC(C)C(O)C(C)(C)COC(=O)C(C)=C JHPBZFOKBAGZBL-UHFFFAOYSA-N 0.000 claims 1
- 239000011521 glass Substances 0.000 abstract description 26
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical group COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 58
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 47
- WOBHKFSMXKNTIM-UHFFFAOYSA-N Hydroxyethyl methacrylate Chemical compound CC(=C)C(=O)OCCO WOBHKFSMXKNTIM-UHFFFAOYSA-N 0.000 description 31
- OZAIFHULBGXAKX-UHFFFAOYSA-N 2-(2-cyanopropan-2-yldiazenyl)-2-methylpropanenitrile Chemical compound N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 description 28
- 102100026735 Coagulation factor VIII Human genes 0.000 description 27
- 101000911390 Homo sapiens Coagulation factor VIII Proteins 0.000 description 27
- OZAIFHULBGXAKX-VAWYXSNFSA-N AIBN Substances N#CC(C)(C)\N=N\C(C)(C)C#N OZAIFHULBGXAKX-VAWYXSNFSA-N 0.000 description 24
- 239000008367 deionised water Substances 0.000 description 19
- 229910021641 deionized water Inorganic materials 0.000 description 19
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 18
- 150000004756 silanes Chemical class 0.000 description 18
- CPUDPFPXCZDNGI-UHFFFAOYSA-N triethoxy(methyl)silane Chemical compound CCO[Si](C)(OCC)OCC CPUDPFPXCZDNGI-UHFFFAOYSA-N 0.000 description 15
- 238000002454 metastable transfer emission spectrometry Methods 0.000 description 13
- 239000000178 monomer Substances 0.000 description 11
- VXUYXOFXAQZZMF-UHFFFAOYSA-N titanium(IV) isopropoxide Chemical compound CC(C)O[Ti](OC(C)C)(OC(C)C)OC(C)C VXUYXOFXAQZZMF-UHFFFAOYSA-N 0.000 description 10
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 9
- 238000006116 polymerization reaction Methods 0.000 description 8
- 238000005266 casting Methods 0.000 description 7
- 238000006243 chemical reaction Methods 0.000 description 7
- 239000002245 particle Substances 0.000 description 7
- 229910001220 stainless steel Inorganic materials 0.000 description 6
- 239000010935 stainless steel Substances 0.000 description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- ZNQVEEAIQZEUHB-UHFFFAOYSA-N 2-ethoxyethanol Chemical compound CCOCCO ZNQVEEAIQZEUHB-UHFFFAOYSA-N 0.000 description 4
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 239000003054 catalyst Substances 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- NKSJNEHGWDZZQF-UHFFFAOYSA-N ethenyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C=C NKSJNEHGWDZZQF-UHFFFAOYSA-N 0.000 description 4
- 125000005395 methacrylic acid group Chemical group 0.000 description 4
- 238000010992 reflux Methods 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 4
- RCMPQDNMLQIDKY-UHFFFAOYSA-N 2-[tris(2-prop-2-enoyloxyethoxy)silyloxy]ethyl prop-2-enoate Chemical compound C=CC(=O)OCCO[Si](OCCOC(=O)C=C)(OCCOC(=O)C=C)OCCOC(=O)C=C RCMPQDNMLQIDKY-UHFFFAOYSA-N 0.000 description 3
- VICHSFFBPUZUOR-UHFFFAOYSA-N 2-[tris[2-(2-methylprop-2-enoyloxy)ethoxy]silyloxy]ethyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCCO[Si](OCCOC(=O)C(C)=C)(OCCOC(=O)C(C)=C)OCCOC(=O)C(C)=C VICHSFFBPUZUOR-UHFFFAOYSA-N 0.000 description 3
- OMIGHNLMNHATMP-UHFFFAOYSA-N 2-hydroxyethyl prop-2-enoate Chemical compound OCCOC(=O)C=C OMIGHNLMNHATMP-UHFFFAOYSA-N 0.000 description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 3
- 239000004925 Acrylic resin Substances 0.000 description 3
- 229920000178 Acrylic resin Polymers 0.000 description 3
- AJTVQQFMXNOEIE-UHFFFAOYSA-N CO[SiH](OC)CC1=CC=C(C=C)C=C1 Chemical compound CO[SiH](OC)CC1=CC=C(C=C)C=C1 AJTVQQFMXNOEIE-UHFFFAOYSA-N 0.000 description 3
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 3
- 150000001298 alcohols Chemical class 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 239000002612 dispersion medium Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 3
- 239000000376 reactant Substances 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- KUDUQBURMYMBIJ-UHFFFAOYSA-N 2-prop-2-enoyloxyethyl prop-2-enoate Chemical compound C=CC(=O)OCCOC(=O)C=C KUDUQBURMYMBIJ-UHFFFAOYSA-N 0.000 description 2
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 2
- 150000004703 alkoxides Chemical class 0.000 description 2
- 238000000137 annealing Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 150000007522 mineralic acids Chemical class 0.000 description 2
- 150000007524 organic acids Chemical class 0.000 description 2
- 229920000620 organic polymer Polymers 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 239000003505 polymerization initiator Substances 0.000 description 2
- 239000007870 radical polymerization initiator Substances 0.000 description 2
- FDNAPBUWERUEDA-UHFFFAOYSA-N silicon tetrachloride Chemical compound Cl[Si](Cl)(Cl)Cl FDNAPBUWERUEDA-UHFFFAOYSA-N 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000003786 synthesis reaction Methods 0.000 description 2
- GQIUQDDJKHLHTB-UHFFFAOYSA-N trichloro(ethenyl)silane Chemical compound Cl[Si](Cl)(Cl)C=C GQIUQDDJKHLHTB-UHFFFAOYSA-N 0.000 description 2
- 239000005050 vinyl trichlorosilane Substances 0.000 description 2
- LTQBNYCMVZQRSD-UHFFFAOYSA-N (4-ethenylphenyl)-trimethoxysilane Chemical compound CO[Si](OC)(OC)C1=CC=C(C=C)C=C1 LTQBNYCMVZQRSD-UHFFFAOYSA-N 0.000 description 1
- RYHBNJHYFVUHQT-UHFFFAOYSA-N 1,4-Dioxane Chemical compound C1COCCO1 RYHBNJHYFVUHQT-UHFFFAOYSA-N 0.000 description 1
- BQTPKSBXMONSJI-UHFFFAOYSA-N 1-cyclohexylpyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C1CCCCC1 BQTPKSBXMONSJI-UHFFFAOYSA-N 0.000 description 1
- HIDBROSJWZYGSZ-UHFFFAOYSA-N 1-phenylpyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C1=CC=CC=C1 HIDBROSJWZYGSZ-UHFFFAOYSA-N 0.000 description 1
- YEKDUBMGZZTUDY-UHFFFAOYSA-N 1-tert-butylpyrrole-2,5-dione Chemical compound CC(C)(C)N1C(=O)C=CC1=O YEKDUBMGZZTUDY-UHFFFAOYSA-N 0.000 description 1
- ZOTQZURPZCTMSC-UHFFFAOYSA-N 2,2-diethoxyethyl(diethoxy)silane Chemical compound C(C)OC(C[SiH](OCC)OCC)OCC ZOTQZURPZCTMSC-UHFFFAOYSA-N 0.000 description 1
- 150000003923 2,5-pyrrolediones Chemical class 0.000 description 1
- STMDPCBYJCIZOD-UHFFFAOYSA-N 2-(2,4-dinitroanilino)-4-methylpentanoic acid Chemical compound CC(C)CC(C(O)=O)NC1=CC=C([N+]([O-])=O)C=C1[N+]([O-])=O STMDPCBYJCIZOD-UHFFFAOYSA-N 0.000 description 1
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 description 1
- IGRYVRNQZARURF-UHFFFAOYSA-N 2-(dimethoxymethylsilyl)ethyl 2-methylprop-2-enoate Chemical compound COC(OC)[SiH2]CCOC(=O)C(C)=C IGRYVRNQZARURF-UHFFFAOYSA-N 0.000 description 1
- JKNCOURZONDCGV-UHFFFAOYSA-N 2-(dimethylamino)ethyl 2-methylprop-2-enoate Chemical compound CN(C)CCOC(=O)C(C)=C JKNCOURZONDCGV-UHFFFAOYSA-N 0.000 description 1
- PFHOSZAOXCYAGJ-UHFFFAOYSA-N 2-[(2-cyano-4-methoxy-4-methylpentan-2-yl)diazenyl]-4-methoxy-2,4-dimethylpentanenitrile Chemical compound COC(C)(C)CC(C)(C#N)N=NC(C)(C#N)CC(C)(C)OC PFHOSZAOXCYAGJ-UHFFFAOYSA-N 0.000 description 1
- WYGWHHGCAGTUCH-UHFFFAOYSA-N 2-[(2-cyano-4-methylpentan-2-yl)diazenyl]-2,4-dimethylpentanenitrile Chemical compound CC(C)CC(C)(C#N)N=NC(C)(C#N)CC(C)C WYGWHHGCAGTUCH-UHFFFAOYSA-N 0.000 description 1
- GMTZHJNNTKYOQK-UHFFFAOYSA-N 2-[methyl-bis(2-prop-2-enoyloxyethoxy)silyl]oxyethyl prop-2-enoate Chemical compound C=CC(=O)OCCO[Si](C)(OCCOC(=O)C=C)OCCOC(=O)C=C GMTZHJNNTKYOQK-UHFFFAOYSA-N 0.000 description 1
- CLYUOMVYYFJUBR-UHFFFAOYSA-N 2-[methyl-bis[2-(2-methylprop-2-enoyloxy)ethoxy]silyl]oxyethyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCCO[Si](C)(OCCOC(=O)C(C)=C)OCCOC(=O)C(C)=C CLYUOMVYYFJUBR-UHFFFAOYSA-N 0.000 description 1
- WDQMWEYDKDCEHT-UHFFFAOYSA-N 2-ethylhexyl 2-methylprop-2-enoate Chemical compound CCCCC(CC)COC(=O)C(C)=C WDQMWEYDKDCEHT-UHFFFAOYSA-N 0.000 description 1
- 125000000954 2-hydroxyethyl group Chemical group [H]C([*])([H])C([H])([H])O[H] 0.000 description 1
- VHSHLMUCYSAUQU-UHFFFAOYSA-N 2-hydroxypropyl methacrylate Chemical compound CC(O)COC(=O)C(C)=C VHSHLMUCYSAUQU-UHFFFAOYSA-N 0.000 description 1
- GWZMWHWAWHPNHN-UHFFFAOYSA-N 2-hydroxypropyl prop-2-enoate Chemical compound CC(O)COC(=O)C=C GWZMWHWAWHPNHN-UHFFFAOYSA-N 0.000 description 1
- WBWAUFJXONIXBV-UHFFFAOYSA-N 2-triethoxysilylethyl acetate Chemical compound CCO[Si](OCC)(OCC)CCOC(C)=O WBWAUFJXONIXBV-UHFFFAOYSA-N 0.000 description 1
- BMYNFMYTOJXKLE-UHFFFAOYSA-N 3-azaniumyl-2-hydroxypropanoate Chemical compound NCC(O)C(O)=O BMYNFMYTOJXKLE-UHFFFAOYSA-N 0.000 description 1
- OFNISBHGPNMTMS-UHFFFAOYSA-N 3-methylideneoxolane-2,5-dione Chemical compound C=C1CC(=O)OC1=O OFNISBHGPNMTMS-UHFFFAOYSA-N 0.000 description 1
- UUEWCQRISZBELL-UHFFFAOYSA-N 3-trimethoxysilylpropane-1-thiol Chemical compound CO[Si](OC)(OC)CCCS UUEWCQRISZBELL-UHFFFAOYSA-N 0.000 description 1
- XDLMVUHYZWKMMD-UHFFFAOYSA-N 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C(C)=C XDLMVUHYZWKMMD-UHFFFAOYSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- JLBJTVDPSNHSKJ-UHFFFAOYSA-N 4-Methylstyrene Chemical compound CC1=CC=C(C=C)C=C1 JLBJTVDPSNHSKJ-UHFFFAOYSA-N 0.000 description 1
- DBCAQXHNJOFNGC-UHFFFAOYSA-N 4-bromo-1,1,1-trifluorobutane Chemical compound FC(F)(F)CCCBr DBCAQXHNJOFNGC-UHFFFAOYSA-N 0.000 description 1
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 239000004342 Benzoyl peroxide Substances 0.000 description 1
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 1
- 101100087530 Caenorhabditis elegans rom-1 gene Proteins 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 1
- YIVJZNGAASQVEM-UHFFFAOYSA-N Lauroyl peroxide Chemical compound CCCCCCCCCCCC(=O)OOC(=O)CCCCCCCCCCC YIVJZNGAASQVEM-UHFFFAOYSA-N 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- NTIZESTWPVYFNL-UHFFFAOYSA-N Methyl isobutyl ketone Chemical compound CC(C)CC(C)=O NTIZESTWPVYFNL-UHFFFAOYSA-N 0.000 description 1
- UIHCLUNTQKBZGK-UHFFFAOYSA-N Methyl isobutyl ketone Natural products CCC(C)C(C)=O UIHCLUNTQKBZGK-UHFFFAOYSA-N 0.000 description 1
- 101100305983 Mus musculus Rom1 gene Proteins 0.000 description 1
- 101100023554 Mycobacterium bovis (strain ATCC BAA-935 / AF2122/97) cmaC gene Proteins 0.000 description 1
- FXHOOIRPVKKKFG-UHFFFAOYSA-N N,N-Dimethylacetamide Chemical compound CN(C)C(C)=O FXHOOIRPVKKKFG-UHFFFAOYSA-N 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 241000083652 Osca Species 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- 241001074085 Scophthalmus aquosus Species 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical group [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- DAKWPKUUDNSNPN-UHFFFAOYSA-N Trimethylolpropane triacrylate Chemical compound C=CC(=O)OCC(CC)(COC(=O)C=C)COC(=O)C=C DAKWPKUUDNSNPN-UHFFFAOYSA-N 0.000 description 1
- TVJPBVNWVPUZBM-UHFFFAOYSA-N [diacetyloxy(methyl)silyl] acetate Chemical compound CC(=O)O[Si](C)(OC(C)=O)OC(C)=O TVJPBVNWVPUZBM-UHFFFAOYSA-N 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 235000011054 acetic acid Nutrition 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000008065 acid anhydrides Chemical class 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 125000005370 alkoxysilyl group Chemical group 0.000 description 1
- SMZOGRDCAXLAAR-UHFFFAOYSA-N aluminium isopropoxide Chemical compound [Al+3].CC(C)[O-].CC(C)[O-].CC(C)[O-] SMZOGRDCAXLAAR-UHFFFAOYSA-N 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
- GXUARMXARIJAFV-UHFFFAOYSA-L barium oxalate Chemical compound [Ba+2].[O-]C(=O)C([O-])=O GXUARMXARIJAFV-UHFFFAOYSA-L 0.000 description 1
- 229940094800 barium oxalate Drugs 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- UWGJCHRFALXDAR-UHFFFAOYSA-N diethoxy-ethyl-methylsilane Chemical compound CCO[Si](C)(CC)OCC UWGJCHRFALXDAR-UHFFFAOYSA-N 0.000 description 1
- JJQZDUKDJDQPMQ-UHFFFAOYSA-N dimethoxy(dimethyl)silane Chemical compound CO[Si](C)(C)OC JJQZDUKDJDQPMQ-UHFFFAOYSA-N 0.000 description 1
- AHUXYBVKTIBBJW-UHFFFAOYSA-N dimethoxy(diphenyl)silane Chemical compound C=1C=CC=CC=1[Si](OC)(OC)C1=CC=CC=C1 AHUXYBVKTIBBJW-UHFFFAOYSA-N 0.000 description 1
- CVQVSVBUMVSJES-UHFFFAOYSA-N dimethoxy-methyl-phenylsilane Chemical compound CO[Si](C)(OC)C1=CC=CC=C1 CVQVSVBUMVSJES-UHFFFAOYSA-N 0.000 description 1
- 238000000635 electron micrograph Methods 0.000 description 1
- ASBGGHMVAMBCOR-UHFFFAOYSA-N ethanolate;zirconium(4+) Chemical compound [Zr+4].CC[O-].CC[O-].CC[O-].CC[O-] ASBGGHMVAMBCOR-UHFFFAOYSA-N 0.000 description 1
- FWDBOZPQNFPOLF-UHFFFAOYSA-N ethenyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C=C FWDBOZPQNFPOLF-UHFFFAOYSA-N 0.000 description 1
- ZLNAFSPCNATQPQ-UHFFFAOYSA-N ethenyl-dimethoxy-methylsilane Chemical compound CO[Si](C)(OC)C=C ZLNAFSPCNATQPQ-UHFFFAOYSA-N 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- RSIHJDGMBDPTIM-UHFFFAOYSA-N ethoxy(trimethyl)silane Chemical compound CCO[Si](C)(C)C RSIHJDGMBDPTIM-UHFFFAOYSA-N 0.000 description 1
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- SBRXLTRZCJVAPH-UHFFFAOYSA-N ethyl(trimethoxy)silane Chemical compound CC[Si](OC)(OC)OC SBRXLTRZCJVAPH-UHFFFAOYSA-N 0.000 description 1
- STVZJERGLQHEKB-UHFFFAOYSA-N ethylene glycol dimethacrylate Substances CC(=C)C(=O)OCCOC(=O)C(C)=C STVZJERGLQHEKB-UHFFFAOYSA-N 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 239000000499 gel Substances 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- VOZRXNHHFUQHIL-UHFFFAOYSA-N glycidyl methacrylate Chemical compound CC(=C)C(=O)OCC1CO1 VOZRXNHHFUQHIL-UHFFFAOYSA-N 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 229940046892 lead acetate Drugs 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- FQPSGWSUVKBHSU-UHFFFAOYSA-N methacrylamide Chemical compound CC(=C)C(N)=O FQPSGWSUVKBHSU-UHFFFAOYSA-N 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- OMNKZBIFPJNNIO-UHFFFAOYSA-N n-(2-methyl-4-oxopentan-2-yl)prop-2-enamide Chemical compound CC(=O)CC(C)(C)NC(=O)C=C OMNKZBIFPJNNIO-UHFFFAOYSA-N 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 150000001451 organic peroxides Chemical class 0.000 description 1
- 125000001181 organosilyl group Chemical group [SiH3]* 0.000 description 1
- 235000006408 oxalic acid Nutrition 0.000 description 1
- RPQRDASANLAFCM-UHFFFAOYSA-N oxiran-2-ylmethyl prop-2-enoate Chemical compound C=CC(=O)OCC1CO1 RPQRDASANLAFCM-UHFFFAOYSA-N 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- FBCQUCJYYPMKRO-UHFFFAOYSA-N prop-2-enyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCC=C FBCQUCJYYPMKRO-UHFFFAOYSA-N 0.000 description 1
- QTECDUFMBMSHKR-UHFFFAOYSA-N prop-2-enyl prop-2-enoate Chemical compound C=CCOC(=O)C=C QTECDUFMBMSHKR-UHFFFAOYSA-N 0.000 description 1
- 238000007717 redox polymerization reaction Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 125000005372 silanol group Chemical group 0.000 description 1
- 239000000741 silica gel Substances 0.000 description 1
- 229910002027 silica gel Inorganic materials 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- UQMOLLPKNHFRAC-UHFFFAOYSA-N tetrabutyl silicate Chemical compound CCCCO[Si](OCCCC)(OCCCC)OCCCC UQMOLLPKNHFRAC-UHFFFAOYSA-N 0.000 description 1
- JSECNWXDEZOMPD-UHFFFAOYSA-N tetrakis(2-methoxyethyl) silicate Chemical compound COCCO[Si](OCCOC)(OCCOC)OCCOC JSECNWXDEZOMPD-UHFFFAOYSA-N 0.000 description 1
- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 description 1
- ZQZCOBSUOFHDEE-UHFFFAOYSA-N tetrapropyl silicate Chemical compound CCCO[Si](OCCC)(OCCC)OCCC ZQZCOBSUOFHDEE-UHFFFAOYSA-N 0.000 description 1
- 239000003017 thermal stabilizer Substances 0.000 description 1
- JMXKSZRRTHPKDL-UHFFFAOYSA-N titanium ethoxide Chemical compound [Ti+4].CC[O-].CC[O-].CC[O-].CC[O-] JMXKSZRRTHPKDL-UHFFFAOYSA-N 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- YZVRVDPMGYFCGL-UHFFFAOYSA-N triacetyloxysilyl acetate Chemical compound CC(=O)O[Si](OC(C)=O)(OC(C)=O)OC(C)=O YZVRVDPMGYFCGL-UHFFFAOYSA-N 0.000 description 1
- PMYRVZBJFIPWMG-UHFFFAOYSA-N triethoxy(2-methoxyethyl)silane Chemical compound CCO[Si](OCC)(OCC)CCOC PMYRVZBJFIPWMG-UHFFFAOYSA-N 0.000 description 1
- DENFJSAFJTVPJR-UHFFFAOYSA-N triethoxy(ethyl)silane Chemical compound CCO[Si](CC)(OCC)OCC DENFJSAFJTVPJR-UHFFFAOYSA-N 0.000 description 1
- JCVQKRGIASEUKR-UHFFFAOYSA-N triethoxy(phenyl)silane Chemical compound CCO[Si](OCC)(OCC)C1=CC=CC=C1 JCVQKRGIASEUKR-UHFFFAOYSA-N 0.000 description 1
- ZNOCGWVLWPVKAO-UHFFFAOYSA-N trimethoxy(phenyl)silane Chemical compound CO[Si](OC)(OC)C1=CC=CC=C1 ZNOCGWVLWPVKAO-UHFFFAOYSA-N 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- NHXVNEDMKGDNPR-UHFFFAOYSA-N zinc;pentane-2,4-dione Chemical compound [Zn+2].CC(=O)[CH-]C(C)=O.CC(=O)[CH-]C(C)=O NHXVNEDMKGDNPR-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/42—Block-or graft-polymers containing polysiloxane sequences
- C08G77/442—Block-or graft-polymers containing polysiloxane sequences containing vinyl polymer sequences
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F292/00—Macromolecular compounds obtained by polymerising monomers on to inorganic materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/02—Polysilicates
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Polymerisation Methods In General (AREA)
- Silicon Polymers (AREA)
Abstract
Abstract of the Disclosure Disclosed is a composite composition obtained by polymerizing a radical-polymerizable vinyl compound (A) in the presence of a silica polycondensate (B) formed by hydrolysis and polycondensation of at least one alkoxysilane compound in a dispersion system of colloidal silica. This composite composition has high transparency, rigidity, toughness and thermal resistance and is hence useful in applications where inorganic glass has heretofore been used.
Description
3 ~ ~
Title of the Invention Composite Composition Having High Transparency and Process for Producing Same Backqround of the Invention 1. Field of the Invention This invention relates to composite compositions having high transparency, rigidity, toughness and thermal resistance.
Title of the Invention Composite Composition Having High Transparency and Process for Producing Same Backqround of the Invention 1. Field of the Invention This invention relates to composite compositions having high transparency, rigidity, toughness and thermal resistance.
2. Description of the Prior Art Generally, organic polymers have low rigi.dity, hardness and thermal resistance. In an attempt to overcome this disadvantage, many investigations have heretofore been made on the formation of composite materials consisting of organic polymers and inorganic substances. For example, there have been proposed a number of methods in which a dispersion of a silica compound ~ormed by polycondensation of an alkoxysilane) or colloidal silica in an acrylic resin solution is used as a coating film for hardening the surfaces of plastic substrates (see, for example, Japanese Patent Laid-Open Nos. 11952/'78 and 11989/'78).
However, when such a composite material is coated on plastic substrates, a coating film having high hardness and high wear resistance is obtained, but no substantial improvement in rigidity can be expected. Moreover, good transparency is obtained at coating film thicknesses of the order of several tens of microns, but a marked reduction in , ' ' ' ' transparency results at greater coating film thicknesses.
On the other hand, it is described in J. Mater. Res., Vol. 4, p. 1018 (1989) that a siiica gel-polymethyl methacrylate composite material having high transparency is obtained by impregnating porous silica gel having a controlled pore diameter with methyl methacrylate monomer and then polymerizing the latter. However, this method has the disadvantage that it involves troublesome steps and is not suitable for industrial purposes and that it is difficult to subject the resulting composite material to postworking.
Summary of the Invention It is an object of the present invention to provide a composite composition to which high rigidity and high thermal resistance have been imparted without impairing the high transparency, high toughness, low specific gravity and good workability inherently possessed by acrylic resins.
According to the present invention, there is provided a composite composition obtained by polymerlzing a radical-polymerizable vinyl compound (A) in the presence of a silica polycondensate formed by hydrolysis and polycondensation of at least one silane compound of the general formula SiRlaR2b(oR3)C (I) where Rl and R2 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or ::
However, when such a composite material is coated on plastic substrates, a coating film having high hardness and high wear resistance is obtained, but no substantial improvement in rigidity can be expected. Moreover, good transparency is obtained at coating film thicknesses of the order of several tens of microns, but a marked reduction in , ' ' ' ' transparency results at greater coating film thicknesses.
On the other hand, it is described in J. Mater. Res., Vol. 4, p. 1018 (1989) that a siiica gel-polymethyl methacrylate composite material having high transparency is obtained by impregnating porous silica gel having a controlled pore diameter with methyl methacrylate monomer and then polymerizing the latter. However, this method has the disadvantage that it involves troublesome steps and is not suitable for industrial purposes and that it is difficult to subject the resulting composite material to postworking.
Summary of the Invention It is an object of the present invention to provide a composite composition to which high rigidity and high thermal resistance have been imparted without impairing the high transparency, high toughness, low specific gravity and good workability inherently possessed by acrylic resins.
According to the present invention, there is provided a composite composition obtained by polymerlzing a radical-polymerizable vinyl compound (A) in the presence of a silica polycondensate formed by hydrolysis and polycondensation of at least one silane compound of the general formula SiRlaR2b(oR3)C (I) where Rl and R2 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or ::
- 3 - ~ 3~
carbon-to-carbon double bond, R3 is a hydrogen atom or a hydrocarbon radical oE 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, a and b are whole numbers of O to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, in a dispersion system of colloidal silica.
Detailed Description of the Preferred Embodiments In the composite compositions of the present invention, the silica skeleton of a silica polycondensate derived from colloidal silica and at least one silane compound hydrolyzed and polycondensed on the surfaces thereo~, and a polymer of a radical-polymerizable vinyl compound form a semi-interpenetrating network structure. Accordingly, the composite compositions of the present invention exhibit very high rigidity, toughness and thermal resistance. Moreover, since the present invention permits colloidal silica particles to be incorporated in the silica skeleton and uniformly dispersed therein, they also exhibit very high transparency.
As the radical-polymerizable vinyl compound (A) used in the present invention, there may be employed a variety of well-known radical-polymerizable monomers. Useful radical-polymerizable monomers include, for example, methacrylic esters such as m~thyl methacrylate, ethyl methacrylate, butyl methacrylate and 2-ethylhexyl methacrylate; acrylic esters such as methyl acrylate, ethyl acrylate, butyl ~ '' 7 ~3 acrylate and 2-e~hylhexyl acrylate; unsaturated carboxylic acids such as acrylic acid, methacrylic acid, maleic acid and itaconic acid; acid anhydrides such as malaic anhydride and itaconic anhydride; maleimide derivatives s~ch as N-phenylmaleimide, N-cyclohexylmaleimide and N-t-butylmaleimide; hydroxyl-containing monomers such as 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate and 2-hydroxypropyl methacrylate;
nitrogen-containing monomers such as acrylamide, methacrylamide, acrylonitrile, methacrylonitrila, diacetone acrylamide and dimethylaminoethyl methacrylate; epoxy-containing monomers such as allyl glycidyl ether, glycidyl acrylate and glycidyl methacrylate; styrene monomers such as styrene and ~methylstyrene; and crosslinking agents such as ethylene glycol diacrylate, ethylene glycol dimethacrylate, allyl acrylate, allyl methacrylate, divinylbenzene and trimethylolpropane triacrylate. Among these monomers, methacrylic esters and acrylic esters are preferred. In the radical-polymerizable vinyl compound (A), at least one monomer selected from methacrylic esters and acrylic esters is preferably present in an amount of not less than 50% by weight and more preferably in an amount of not less than 70%
by wei~ht. Especially preferred monomers for use as the radical-polymerizable vinyl compound (A) are methacrylic esters.
Moreover, vinyl compounds having in the molecule at least one group reactive with the silanol groups contained in the silica polycondensate (B) (i.e., at least one functional group selected from the class consisting of hydroxyl, carboxyl, halogenated silyl and alkoxysilyl groups) function to further improve some properties (such as rigidity, toughness and thermal resistance~ of the resulting composite composition. Accordingly, it is preferable that such a vinyl compound be contained as a component of the radical-polymerizable vinyl compound ~A).
Such vinyl compounds having a reactive group in the molecule include, for example, 2-hydroxyethyl (meth)-acrylate, 2-hydroxypropyl (meth)acrylate, (meth)acrylic acid, vinyltrichlorosilane, vinyltrimethoxysilane and y-methacryloyloxypropyltrimethoxysilane. Among these vinyl compounds, 2-hydroxyethyl methacrylate, methacrylic acid, vinyltrichlorosilane, vinyltrimethoxysilane and Y-methacryloyloxypropyltrimethoxysilane are especially preferred.
The silica polycondensate (B) used in the present invention is a product obtained by hydrolysis and polycondensation of at least one silane compound of the general formula SiR1aR2b(oR3)C (I) where Rl and R2 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or , ' Y~
2 ~
carbon-to-carbQn double bond, R3 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, a and b are whole numbers of 0 to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, in a dispersion system of colloidal silica. During this reaction, most of the oR3 groups contained in the silane compound are hydrolyzed, but some oR3 groups, or some oR3 and OH groups, still remain on the ou~er surfaces of the silica polycondensate (B). Therefore, the silica polycondensate (B) dissolves in the radical-polymerizable vinyl compound (A).
The above-described silica polycondensate (B) can be uniformly dispersed in the radical-polymerizahle vinyl compound (A) even at such silica concentrations that the dispersion of colloidal silica alone in ~he radical-polymerizable vinyl compound (A) would cause gelation. That is, the present invention makes it possible to disperse a high concentration of silica uniformly in the resulting composite composition and hence impart desired properties thereto.
As the dispersion of colloidal silica used in the present invention, there may employed a variety of commercial products. The particle diameter of colloidal silica usually ranges ~rom 1 nm to 1 ~m, but no particular limitation is placed on the particle diameter. However, preferred particle diameters are within the range oE 5 to 500 nm. Although no particular limitation is placed on the dispersion medium for colloidal silica, water, alcohols (such as methanol and isopropyl alcohol), cellosolves, dimethylacetamide and the like are usually used. Especially preferred dispersion media are alcohols, cellosolves and water.
Among the silane compounds within the scope of the above general formula (I), silane compounds represented by the following general formulas (II) to (VII) are preferred.
SiR4aR5b(oR6)C (II) SiR4n(0-CH2CH2-o-Co-(R7)C=CH2)4_n (III) CH2=C(R7)Coo(CH2)pSiR8n(0R6)3_n (IV) CH2=CHSiR8n~0R6)3 n (V) HS(CH2)psiR8n(0R6)3-n (VI) and CH2 1 ~ -SiR3n(0R6)3-n (VII) where R4 and R5 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, R7 is a hydrogen atom or a methyl group, R8 is an alkyl group of 1 to 3 carbon atoms or a phenyl group, a and b are whole numbers of O to 3, c is equal to (4-a~b) and represents a whole number of 1 to 4, n i9 a whole number of , ~ J~
O to 2, and p is a whole number of 1 to 6.
The silane compounds represented by the above general formula (II) include, for example, tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, tetrabutoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, dimethyldimethoxysilane, diphenyldimethoxysilane, methylethyldiethoxysilane, methylphenyldimethoxysilane, trimethylethoxysilane, methoxyethyltriethoxysilane, acetoxyethyltriethoxysilane, diethoxyethyldiethoxysilane, tetraacetoxysilane, methyltriacetoxysilane, tetrakis(2-methoxyethoxy)silane and partial hydrolyzates thereof. The silane compounds represented by the above general formula (III) include, for example, tetrakis(acryloyloxyethoxy)silane, tetrakis(methacryloyloxyethoxy)silane, methyltris(acryloyloxyethoxy)silane and methyltris(methacryloyloxyethoxy)silane. Among them, tetrakis(acryloyloxyethoxy)silane and tetrakis(methacryloyloxyethoxy)silane are preferred. These silane compounds can be synthesized, for example, from tetrachlorosilane and 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate. The silane compounds represented by the above general formula (IV) include, ~or example, ~-acryloyloxyethyldimethoxymethylsilane, t 2~
~-acryloyloxypropylmethoxydimethylsilane, r-acryloyloxypropyltrimethoxysilane~ ~_ methacryloyloxyethyldimethoxymethylsilane, y-methacryloyloxypropylmethoxydimethylsilane and ~-methacryloyloxypropyltrimethoxysilane. The silane compounds represented by the above general formula (v) include, for example, vinylmethyldimethoxysilane, vinyltrimethoxysilane and vinyltriethoxysilane. The silane compounds represented by the above general formula (VI) include, for example, y-mercaptopropyldimethoxymethylsilane and Y mercaptopropyltrimethoxysilane. The silane compounds represented by the above general formula (VII) include, for example, p-vinylphenylmethyldimethoxysilane and p-vinylphenyltrimethoxysilane.
In the practice of the present invention, the silane compounds represented by the above general formulas (II) to (VII) are preferably used in any of the following five embodiments.
In a first embodiment, at least one silane compound of the above general formula ~II) is used.
In this embodiment, it is preferable to use silane compounds of the abo~e general formula (Il) in which R4, R5 and R6 are hydrocarbon radicals of 1 to 4 carbon atoms.
Where R4, R5 and R6 are hydrocarbon radicals of 4 or less carbon atoms, no significant steric hindrance results.
~ccordingly, the hydrolysis and polycondensation rate 2~ J'~
becomes so high that colloidal silica particles are readily bonded together to form a silica skeleton. Especially preferred silane compounds are tetraalkoxysilanes of the above general formula (II) in which c is equal to 4. In this case, tetraalkoxysilanes are preferably used either alone or in admixture with trialkoxysilanes or dialkoxysilanes to improve stability prior to polymerization.
In a second embodiment, at least one silane compound of the above general formula ~III) is used.
When silane compounds of the general formula (III) are hydrolyzed and polycondensed, some acryloyloxyethoxy or methacryloyloxyethoxy groups are not hydrolyzed and remain in the silica polycondensate (B). During polymerization, these unhydrolyzed acryloyloxyethoxy or methacryloyloxyethoxy groups copolymerize with the radical-polymerizable vinyl compound (A) and chemically combines therewith, thus servîng to reinforce the interface between the polymer of the radical-polymerizable vinyl compound (A) and the silica polycondensate (B).
When the radical-polymerizable vinyl compound (A) is polymerized in the presence of the silica polycondensate (B), some of the unhydrolyzed acryloyloxyethoxy or methacryloyloxyethoxy groups may be el.iminated owin~ to further polycondensation of the silica polycondensate (B).
~t~ ? ~3 Even in thi~ c~se, the eliminated groups copolymerize with the radical-polymeriæable vinyl compound (A) and do not form any volatile component. Accordingly, the finally obtained composite compositions will not suffer foaming, cracking or fracture.
In a third embodiment, at least one silane compound of the above general formula (II) and at least one silane compound of the above general formula (III) are used in combination.
Where these two types of silane compounds are used in combination, the resulting silica polycondensate (B) not only shows the above-described effects produced when each type of silane compound is used alone, but also has resistance to hydrolysis because the silane compound of the general formula (III) is sterically crowded around the silicon atom. Thus, the combined use of these two types of silane compounds is effective in keeping the silica polycondensate (B) stable till the polymerization procedure which will be described later.
In a fourth embodiment, at least one silane compound of any of the above general formulas (IV) to (VII) is used.
Since silane compounds of the general formulas (IV) to (VII) and their hydrolyzates also act as copolymerizable monomers or chain transfer agents during polymerization of the radical-polymerizable vinyl compound (A), they serve to reinforce the interface between the polymer of the radical-' . I
, polymerizable vinyl compound (A) and the silica polycondensate (B) and thereby impart good proper~ies to the finally obtained composite compositions.
In the fifth embodiment, at least one silane compound of the above general formula (II~ and at least one silane compound of any of the above general formulas (IV) to (VII) are used in combination.
Where these two types of silane compounds are used in combination, the silane compound of any of the general formulas (IV) to (VII) is incorporated in the silica skeleton formed from the silane compound of the general formula (II) as described above in connection with the first embodiment. Thus, a stronger bond is produced between the polymer of the radical-polymerizable vinyl compound (A) and the silica polycondensate (B) to impart good properties to the finally obtained composite compositions.
In order to form the silica polycondensate (B) by hydrolysis and polycondensation of the above-defined silane compound in a dispersion system of colloidal silica, the silane compound may be used alone or in combination wi-th a minor amount of a component co-condensable therewith.
Useful components co-condensable with the above-enumerated silane compounds include, for example, metallic alkoxides, organic metallic salts and metallic chelates. Such co-condensable components are preferably used in an amount of O
. .
, `
. 3~3' to 100 parts by weight, more preferably O to 50 parts by weight, per 100 parts by weight of the silane compound.
Specific examples of such co-condensable metallic alkoxides, organic metallic sal~s and metallic chelates include titanium tetraethoxide, titanium tetraisopropoxide, zirconium tetraethoxide, ~irconium tetra-n-butoxide, aluminum triisopropoxide, zinc acetylacetonate, lead acetate and barium oxalate.
In the hydrolysis and polycondensation reaction of the silane compound, water needs to be present in the reaction system. Generally, the proportion of water present in the reaction system exerts no significant lnfluence on the reaction rate. However, if the amount of water is extremely small, the hydrolysis is too slow to form a polycondensate.
In the hydrolysis reaction of the silane compound, an inorganic or organic acid can be used as a catalyst. Useful inorganic acids include, for example, hydrohalogenic acids (such as hydrochloric acid, hydrofluoric acid and hydrobromic acid), sulfuric acid, nitric acid and phosphoric acid. Useful organic acids include, for example, formic acid, acetic acid, oxalic acid, acrylic acid and methacrylic acid.
In the reaction system for hydrolysis of the silane compound, a solvent may be used in order to effect the reaction mildly and uniformly. It is desirable that the solvent allows the reactant (i~e., silane alkoxide), water ~'7 ~ 14 -and the catalyst to be intermixed. Useful solvents include, for example, water; alcohols such as methyl alcohol, e-thyl alcohol and isopropyl alcohol; ketones such as ace~one and methyl isobutyl ketone; and ethers such as t~trahydrofuran and dioxane. For this purpose, the above-described dispersion medium for colloidal silica may be used as it is, or any necessary amount of solvent may be added anew. No particular limi~ation is placed on the amount of solvent used, so long as the reactant can be dissolved homogeneously. However, if the concentration of the reactant is too low, the reaction rate may become unduly slow. The hydrolysis and polycondensation reaction of the silane compound is usually carried out at a temperature ranging from room temperature to about 120C for a period of about 30 minutes to about 24 hours, and preferably at a temperature ranging from room temperature to about the boiling point of the solvent for a period of about 1 to about 10 hours.
In the silica polycondensate (B), no particular limitation is placed on the proportions of colloidal silica and the silane compound of the general formula (I).
However, the silane compound is preferably used in an amount of 0.1 to 2,000 parts by weight, more preferably 1 to 1,000 parts by wei~ht, per 100 parts by weight of the colloidal silica solid component.
.
' ' ' , '~
2~J~
Where the silane compound comprises at least one compound of the general formula (II), the silane compound is preferably used in an amount of 5 to 2,000 parts by weight, more preferably 10 to 1,000 parts by weigh-t, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises at least one compound of the general formula (III), the silane compound is preferably used in an amount of 1 to 2,000 parts by weight, more preferably 5 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises a combination of at least one compound of the general formula (II) and at least one compound of the general formula (III), the compound of the general formula (II) is preferably used in an amount of 5 to 2,000 parts by weight, more preferably 10 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component, and the compound of the general formula (III) is preferably used in an amount of 0.1 to 2,000 parts by weight, more preferably 1 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises at least one compound of any of the general formulas (IV) to (VII), the silane compound is preferably used in an amount of 1 to 2,000 parts by weight, more preferably 5 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises a combination of at least one compound o the general formula (II) and at least one compound of any of the general formulas (IV) to (VII), the compound of the general formula (II) is preferably used in an amount of 5 to 2,000 parts by weight, more preferably 10 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component, and the compound of any of the general formulas (IV) to (VII) is preferably used in an amount of 0.1 to 2,000 parts by weight, more preferably 1 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
The composite compositions of the present invention contain a silica polycondensate (B) formed by hydrolysis and polycondensation of a silane compound in a dispersion system of colloidal silica, and a polymer of a radical-polymerizable vinyl compound (A). The proportions of the radical-polymerizable vinyl compound (~) and the silica polycondensate (B) are preferably chosen so that the components (A) and (B) are present in amounts of 1 to 99% by wei~ht and 99 to 1% by weight, respectively. More preferably, the components (A) and (B) are used in amounts of 10 to 90% by weight and 90 to 10% by weight, respectively. Most preferably, the components (A) and (B~
are used in amounts of 20 to 80~ by wei~ht and 80 to 20% by - ~ - . ; ~ : .
- 17 _ ~,w~
weight, respectively. When the silica polvcondensate (B) is used in an amount of 80 to 20% by weight, the properties desired in the present invention are manifested to a full degree.
The composite compositions of the present invention are preferably produced by mixing the radical-polymerizable vinyl compound (A) and the silica polycondensate (B) in a desired state and polymerizing them concurrently.
Alternatively, they may be produced by partially polymerizing the radical-polymerizable vinyl compound (A) in advance, mixing this partial polymer of the radical-polymerizable vinyl compound (A) and the silica polycondensate, and polymerizing them.
Even when the SiO2 content is 15% by weight or greater, the composite compositions of the present invention have a haze of not greater than 5% as measured at a plate thickness of 3 mm. Electron micrographs reveals that colloidal silica particles are very uniformly dispersed without suffering agglomeration. This means that, in the composite compositions of the present invention, colloidal silica particles are incorporated in the silica skele~on formed by hydrolysis and polycondensation of at least one ~ilane compound and intermingled with the polymer of the radical-polymerizable vinyl compound (A) on a molecular level, thus permitting the achievement of high transparency. In the case of acrylic resins having fine silica particles simply , dispersed therein, their haze as measured at a plate thickness of 3 mm is greater than 20% at SiO2 contents of 15~ by weight or greater, thus showing a marked reduction in transparency.
Although no particular limitation is placed on the method by which the composite compositions of the present invention are produced, it is preferable to produce them according to the conventionally known cast polymeri~ation process. By way of example, the cast polymerization process starts with mixing the radical-polymerizable vinyl compound (A) in the form of a monomer or a partial polymer with the silica polycondensate (B). The solvent and water remaining in this mixture are distilled off to obtain a mixed solution comprising the component (B) dissolved in the component (A).
Then, a casting material is prepared by adding a radical polymerization initiator to the mixed solution. More specifically, the mixing of both components is carried out, for example, by mixing the component (A) directly with a solution of the silica polycondensate (B) in a suitable solvent and then removing the solvent and water associated with the component (B), or by adding the component (A) to a solution of the silica polycondensate (B) while removing therefrom the solvent and water associated with the component (B). Thus, it is important to prepare a mixed solution of both components without causing the component . ''' '.
~ r ~
(B) to separate out as a solid. It is to be understood that the above-described mixed solution can have any viscosity, so long as the component (B) is homogeneously dissolved in the component (A). For example, the mixed solution may have the form of a gel-like material.
The radical polymerization initiators which can be used for this purpose include, for example, azo compounds such as 2,2'-azobisisobutyronitrile, 2,2'-azobis(2,4-dimethylvaleronitrile) and 2,2'-azobis(2,4-dimethyl-4-methoxyvaleronitrile); organic peroxides such as benzoyl peroxide and lauroyl peroxide; and redox polymerization initiators.
This casting material can be cast-polymerized by the cell casting process in which a cell is formed by two surface-treated inorganic glass or metal plates disposed in opposed relationship and ssaled with a gasket at their periphery, and the casting material is poured into the cell and heated; or the continuous casting process in which a casting space is defined by two stainless steel endless belts having one mirror-polished surface and traveling in the same direction at the same speed, and two gaskets disposed along the edges of the belts, and the above-described casting material is continuously poured into the casting space from the upstream side and heated. The polymerization temperature at which the composi~e compositions of the present invention are produced is , ~. , , 2~'~J ~,~? 9 _ 20 --usually within the range of 10 to 150C. However, it is preferable to form a composite composition by efecting polymerization of the radical-polymerizable vinyl compound (A) and further polycondensation of the silica polycondensate (B) concurrently at a temperature above room temperature, i.e., within the r~nge of 40 to 150C.
Furthermore, in any convenient step of the present process, various additives such as colorants, ultraviolet absorbers, thermal stabilizers and mold releasing agents may be incorporated in the composite composition in such amounts as not to impair the effects of the present invention.
The present invention is more specifically explained with reference to the following examples. However, it is to be understood that the present invention is not limited thereto. In these examples, all parts are by weight unless otherwise stated.
Transparency was evaluated by using an integxating sphere type haze meter (SEP-H-SS; manufactured by Japan Precision Optics Co., Ltd.) to measure the total light transmittance and haze of a sample according to ASTM D1003.
Thermal resistance was evaluated by annealing a sample and then measuring its heat distortion temperature (HDT) according to ASTM D648. Strength was evaluated by annealing a sample at 1~0C for 60 hours and then making a bending test of the sample according to ASTM D790 to determine its ,.
~ ' .
flexural breaking strength and flexural modulus of elasticity.
Example 1 A glass flask fitted with agitating blades was charged with 98.8 parts of tetraethoxysilane (hereinafter abbreviated as TES~ and 100 parts of colloidal silica dispersed in isopropyl alcohol so as to have a silica content of 30% by weight (commercially available from Catalyst Chemical Industry Co., Ltd. under the trade name of OSCA~-1432; hereinafter abbreviated as S-1). While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C.
After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while methyl methacrylate (hereinafter abbreviated as MM~) was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixture was concentrated to a tatal amount of 150 parts ~a solid content (i.e., silica polycondensate (B) content) of about 40% by weight).
Then, 0.15 part of 2,2'-azobisisobutyronitrile (hereinafter abbreviated as AIBN) as a polymerization initiator was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it ., was poured into a cell formed by a g~sket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 2 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 4.5 parts of methyltriethoxysilane (hereinafter abbreviated as MTES), 100 parts of colloidal silica S-l and 80 parts of ethanol. While the contents o~
the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amountn of 150 parts (a solid content of about 40%
by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in , .: , Example 1 to obtain a cast pla~eO Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 3 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 4.5 parts of MTES and 100 parts of colloidal silica dispersed in methyl alcohol so as to have a silica content of 30% by weight (commercially available from Catalyst Chemical Industry Co., Ltd. under the trade name of OSCAL-1132; hereinafter abbreviated as S-2). While the contents of the flask were being stirred, 36 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the resultin~ mixture was heated under reflux. After 2 hours, the mixture was cooled and 100 parts of 2-hydroxyethyl methacrylate (hereinafter abbreviated as HEMA~ was added ~hereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 170 parts of a mixed solution (a solid content of about 36% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown - 24 - ~ 3~
in Table 1.
Example 4 A glass flask fitted with agitating blades was charged with 22.3 parts of MTES and 200 parts of colloidal silica S-l. While the contents of the flask were being stirred, 14 parts of deionized water and 0.5 part of 36 wt.%
hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, 10 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 135 parts (a solid content of about 50% by weight).
Then, 0.13 part of AIBN was added to 135 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 5 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 4.5 parts of MTES and 100 parts of colloidal silica S-l. While the contents of the flask were : : ~
, ', ,"~
- : . . . . .
~s ~ 3~1 ~
being stir~ed, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid ware added thereto and the ~emperature was raised to 70C. After 2 hours, ~he mixture was cooled to 0C and added slowly to a s-tirred solution which had been prepared by dissolving 5.0 parts of titanium tetraisopropoxide (hereinafter abbreviated as TTIP) in 50 parts of isopropyl alcohol and had previously been cooled to 0C. Thereafter, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. ~inally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated ko a total amount of 150 parts (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, th~ mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 6 A glass flask fitted with agitating blades was charged with 22.3 parts of MTES and 300 parts of colloidal silica dispersed in water so as to have a silica content of 20% by weight (commercially available from Nissan Chemical Industries, Ltd. under the trade name of Snowtex-0;
hereinaftex abbrevia~ed as S-3). While the contents of the flask were being stirred, 0.5 part of 36 wt.~ hydrochloric acid was added thereto and the resulting mixture was heated to 7QC. After 2 hours, the mixture was cooled and 100 parts of HEMA ~as added thereto. After 100 parts of ethyl cellosolve was added in order to form an azeotropic mixture with water, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 170 parts of a mixed solution (a solid content of about 40~ by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, ~he mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown ~n Table 1.
Examples 7-9 Cast plates were obtained in exactly the same manner as described in Example 1, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used were altered as shown in Table 1.
Properties of these cast plates wexe evaluated and the results thus obtained are shown in ~able 1.
Comparative Exam~le 1 ? ~
0.15 part of AIBN was dissolved in 150 parts of MMA.
This mixture was polymerized in the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Comparative Example 2 An at~empt was made to prepare a solution having a solid content of 30% by weight from colloidal silica and MMA. Specifically, the volatile components were distilled off from 100 parts of colloidal silica S-l at 40C under reduced pressure by means of a rotary evaporator, while MMA
was added at the same rate as the volatile components were distilled off. However, before khe solvent was completely replaced by MMA, the solution showed an abrupt increase in viscosity and formed a gel, which made it impossible to subject the solution to the polymerization procedure.
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Table 1 Radical- Colloidal Silane Total ~ Flexural Flexural Example polymer- silica compound Solid light Haze HDT breaking modulus No. izable ~ con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance ticit2 compound (parts) (parts) (wt.Z) (Z) (%) (C) (kg/om2) (kglcm ) Example 1 MMA S-l 100 TES98.8 4o----- 93.6 2.7 185 1,200 4.8x104 a 2 MMA S-l 100 TES98.8 40 93.3 2.6 164 1,230 4.5x104 MTES4.5 _ . . ~ _ a 3 HEMA S-2 100 TES 98.8 36 92.6 3.6 159 1,240 6.2x104 MTES 4.5 _ n 4 MMA S-l 200 MTES 22.3 50 92.5 2.9 148 1,200 5.7x104 HEMA
.
MMA S-l 100 TES98.8 40 92.2 3.8 160 1,200 5.8x104 . _ MTES4.5 .
n 6 HEMA S-3 300 MTES - 22.3 40 92.4 3.6 145 1,200 5.2x104 _ _ MMA S-l 150 TES36.0 38 93.3 2.5 166 1,230 5.5x104 MTES, 3.5 ~
_ 8 MMA S-l 200 TES49.1 50 92.3 2.6 202 . 1,200 7.3x104 MTES4.7 n g MMA S-l 100 TES98.8 20 93.6 1.7 150 1,200 4.1x104 _ _ _ _ Comparative Example 1 _ _ _ _ _ 92.1 1.3 100 1,200 3.5x104 _ Synthesis Example While 208 parts of HEMA was being stirred at room temperature, 68 parts of tetrachlorosilane was added dropwise thereto over a period of 4 hours. After completion of the addition, the stirring was continued for 0.5 hour and the temperature was then raised to 50C. After an hour, the volatile components were completely removed by means of a rotary evaporator to obtain tetrakis(methacryloyloxyethoxy)-silane ~hereinafter abbreviated as TMES).
Moreover, tetrakis(acryloyloxyethoxy)silane thereinafter abbreviated as TAES) was obtained in the same manner as described above, except that 208 parts of HEMA was replaced by 186 parts of 2-hydroxyethyl acrylate.
Example 10 A glass flask fitted with agitating blades was charged with 32.6 parts of the TMES prepared in Synthesis Example and 240 parts of colloidal silica S-1. While the contents of the flask were being stirred, 8.6 parts of deionized water and 0.1 part of 36 wt.~ hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the volatile components were distilled off at 40C
under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution , , .
, was concentrated to a total amount of 150 parts (a solid content of about 50~ by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell formed by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate.
Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
Example 11 A glass flask fitted with agitating blades was charged with 32.6 parts of TMES and 240 parts of colloidal silica S-l. While the contents of the flask were being stirred, 4.3 parts of deionized water and 0.1 part of 36 wt.~
hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the mixture was cooled and 75 parts of HEMA was added thereto. Then, the volatile components were distiIled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. I'hus, there was obtained 150 parts of a mixed solution (a solid content of about 50~ by weight).
?
~ 31 -Thenr 0.15 part of AIBN was added to lS0 parts of the above mixed solution. Thereaftex, the mixed solu~ion was polymerized in exactly the same manner as described in Example 10 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
Example 12 A glass flask fitted with agitating blades was charged with 32.6 parts of TMES and 240 par~s of colloidal silica S-2. While the contents of the flask were being stirred, 4.3 parts of deionized water and 0.1 part of 36 wt.%
hydrochloric acid were added thereto and the resulting mixture was heated under reflux. After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finallyr the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 150 parts (a solid content of about 50% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 10 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
J~ f~
Example 13 A glass flask fitted with agitating blades was charged with 27.2 parts of TMES and 300 parts of colloidal silica S-3. While the contents of the flask were being stirred, 0.5 part of 36 wt.% hydrochloric acid was added thereto and the resulting mixture was heated to 70C. After 2 hours, the mixture was cooled and 95 parts of HEMA was added thereto. After 100 parts of ethyl cellosolve was added in order to form an azeotropic mixture with water, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 157 parts of a mixed solution (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exac~ly the same manner as described in Example 10 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
Examples 14-16 Cast plates were obtained in exactly the same manner as described in Example 10, except that the types and amounts of radical-polymeriæable vinyl compound, colloidal silica and silane compound used and the solid content of the mixed ~t~?,~
solution were altered as shown in Table 2. Properties of these cast plates were evaluated and the results thus obtained are shown in Table 2.
- 3~ -Table 2 Radical- ColloidalSilane Total Flexural Flexural Example polymer- silicacompoundSolid light Haze HDT breaking modulus No. izable con- trans- strength of elas_ vinyl Type Amount Type Amount tent mittance 2 ticity~
compound(parts) (parts) (wt.%) (%) (%) (C) (kg~cm ) (kg/cm ) _ _ Example 10 MMA S-l 240 TMES 32.6 50 93.2 1.6 151 1,250 7.7x104 n11 HEMA S-l 240 TMES 32.6 50 93.3 2.5 146 1,250 7.6x104 . _ ~
n12 MMAS-2 240 TMES 32.6 5092.9 1.7 152 1,200 7.6x104 . __ n13 HEMA S-3 300 TMES27.2 4092.6 2.7 144 1,200 6.8x104 n14 MMAS-l 240 TAES 29.3 5093.2 1.6 143 1,250 6.3x104 _ "15 MMAS-l 100 TMES 13.0 2093.0 1.6 135 1,230 5.0x104 ~ _ n16 MMA S-l 240 ,~MES.65.2 4093.1 1.5 149 1,250 6.5x104 _ _ :; . ' ., - 35 - 2~ 9 ExamPle 17 A glass flask ~itted with agitatin~ blades was charged with 41.6 parts of TES, 27 . 2 parts of TMES and 200 parts of colloidal silica S-l. While the contents of the flask were being stirred, 9 parts of deionized water and 0.2 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised -to 70C.
After 2 hours, the volatile components ~ere distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount o~ 150 parts ~a solid conte~t of about 50% by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mi~ed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell forrned by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 5 hours and then at 130C for 2 hours to obtain a cast plate.
Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 18 A glass flask fitted with agitating blades was charged with 41.6 paxts of TES, 27.2 parts of TMES and 200 parts of colloidal silica S-2. While the contents of the flask were being stirred, 36 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the resulting mixture was heated under reflux.
After 2 hours, the mixture was cooled and 75 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 150 parts of a mixed solution (a solid content of about 50% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 19 A glass flask fitted with agitating hlades was charged with 26.7 parts of ~TES, 27.2 parts of TMES and 200 parts of colloidal silica S-l. While the contents of the flask were being stirred, 14 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and ~he temperature was raised to 70C.
- , ,:~
- 37 _ After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resultin~
mixed solution was concentrated to a total amount of 144 parts (a solid content of about 50~ by weight).
Then, 0.13 part of AIBN was added to 135 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 20 A glass flask fitted with agitating blades was charged with 41.6 parts of TES, 27.2 parts of TMES and 200 parts of colloidal silica S-1. While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C.
After 2 hours, the mixture was cooled to 0C and added slowly to a stirred solution which had been prepared by dissolving 5.0 parts of TTIP in 50 parts of isopropyl alcohol and had previously been cooled to 0C. Thereafter, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA
,.
:
was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount o~ 190 parts (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 21 A glass flask fitted with agitating blades was charged with 26.7 parts of MTES, 27.2 parts of TMES and 300 parts of colloidal silica S-3. While the contents of the flask were being stirred, 0.5 part of 36 wt.~ hydrochloric acid was added thereto and the resulting mixture was heated to 70C.
After 2 hours, the mixture was cooled and 100 parts of HEMA was added thereto. After 100 parts of ethyl cellosolve was added in order to form an azeotropic mixture with water, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off ~y means of a vacuum pump. Thus, there was obtained 180 parts of a mixed solution (a solid content of about 40% by weight).
~, ~ ' J~?~
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cas~ plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
ExamPles 22-24 Cast plates were obtained in exactly the same manner as described in Example 17, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used were altered as shown in Table 3.
Properties of these cast plates were evaluated and the results thus obtained are shown in Table 3.
2~
Table 3 Radical- ColloidalSilane Total Flexural Flexural Example polymer- silicacompound Solid light Haze HDT breaking modulus No. izable con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance tiCitY2 compound (parts) (parts) (wt.Z) (%) (%) (C) (kg/cm2) (kglcm ) _ _ _ Example 17 MMA S-1 200 TES 41.6 50 92.8 2.7 153 1,210 7.3x104 TMES 27.2 . . _ _ n 18 HEMA S-2 200 TES 41.6 50 92.6 2.8 156 1,220 7.2x104 TMES 27.2 _ n 19 ~MA S-l 200 MTES 26.7 50 92.5 2.8 142 1,200 6.6x104 TMES 27.2 i _ _ _ n 20 MMA S-l 200 TES 41.6 40 91.8 2.9 155 1,210 6.7x104 TMES 27.Z _ ~
n 21 HEMA S-3 300MTES 26.7 40 92.6 3.2 141 1,200 6.4x104 TMES 27.2 _ _ n 22 MMA S-l 200 TES 41.6 50 92.6 2.6 136 1,250 5.9x104 _ TAES 24.4 _ n 23 MMA S-l 100 TES 20.8 20 93.0 1.7 134 1,230 5.1x104 . TMES 18.6 __ _ n , 24 MMA S-l 240 TES 10.4 55 92.8 - 2.6 176 1,210 7.9x104 TMES 27.2 _ ,, ~
. .
' . ' ~.
3 ,~ ~
~, ~ 41 -Example 25 A glass flask fitted with agitating blades was charged with 29.8 parts of ~methacryloyloxypropyltrimethoxysilane (hereinafter abbreviated as MPTMS) and 240 parts of colloidal silica S-l. While the contents of the flask were being stirred, 6.5 parts of deionized water and 0.1 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off.
Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 158 parts (a solid content of about 50% by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell formed by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate.
Properties of this cast plate were evaluated and the results thus obtained are shown in Table 4.
Example 26 A glass flask fitted with agitating blades was charged 3 ~ ~
with 17.8 parts of vinyltrimethoxysilane (hereinafter abbreviated as VTMS) and 240 parts of colloidal silica S-1.
While the contents of the flask were being stirred, 6.5 parts of deionized water and 0.1 part of 36 wt.%
hydrochloric acid were added thereto and ~he resulting mixture was heated to 70C. After 2 hours, the mixture was cooled and 10 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressuxe by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 158 parts (a solid content of about 50% by weight)~
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 25 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 4.
Example 27 A glass flask fitted with agitating blades was charged with 29.8 parts of MPTMS and 240 parts of colloidal silica S-2. While the contents of the flask were being stirred, 6.5 parts of deionized water and 0.1 part of 36 wt.%
:
,'~' ' ' ' , .
.
- ~3 -hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the mixture was cooled and 75 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means o~ a vacuum pump. Thus, there was obtained 158 parts of a mixed solution (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 25 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 4.
Examples 28-32 Cast plates were obtained in exactly the same manner as described in Example 25, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used and the solid content of the mixed solution were altered as shown in Table 4. Properties of these cast plates were evaluated and the results thus obtained are shown in Table 4.
2~ l ~o~
Table 4 Radical- ColloidalSilane Total Flexural Flexural Example polymer- silicacompoundSolid light Haze HDT breaking modulus No. izable con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance 2 ticitY2 compound (parts) (parts) (wt.%) (Z) (%) (C) (kg/cm ) (kglcm ) Example 25 ~MA S-l 240 MPTMS 29.8 50 93.5 2.6 192 1,220 8.7x104 26 MMA S-l 240 VTMS17.8 50 93.4 2.5 186 1,220 8.6x104 HEMA
n 27 HEMA S-2 240 MPTMS 29.8 50 93.1 2.7 185 1,200 8.4x104 n 28 MMA S-l 240 MCTMS 23.6 50 93.0 2.7 190 1,200 8.3x104 n 29 MMA S-l 240 MPDMS 27.8 50 93.1 2.7 167 1,250 7.8x104 _ n 30 MMA S-l 100 VTMS3.5 20 93.4 1.8 165 1,250 5.0x104 a 31 MMA S-l 240 VTUS35.5 40 93.5 2.5 17a 1,250 6.9x104 n 32 MMA S-l 240 VPDMS 26.4 40 93.0 2.5 162 1,200 6.5xlo4 The abbreviations used in Table 4 are as follows:
MCTMS: r-mercaptopropyltrimethoxysilane MPDMS: y~Methacryloyloxypropyldimethoxymethylsilane VPDMS: p-Vinylphenylmethyldimethoxysilane Example 33 A glass flasX fitted with agitating blades was charged with 98.8 parts of TES, 6.2 parts of MPTMS, 100 parts of colloidal silica S-l and 80 parts of ethanol. While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C
After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by ~MA and the resulting mixed solution was concentrated to a total amount of 150 parts (a solid content of about 40~ by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell formed by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate.
.
~ f ~ 3"~3 Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 34 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 6.2 parts of MPTMS and 100 parts of colloidal silica S-2. While the contents of the flask were being stirred, 36 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the resulting mixture was heated under reflux.
After 2 hours, the mixture was cooled and 100 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 170 parts of a mixed solution (a solid content of about 36% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 35 A glass flask fitted with agitatin~ blades was charged with 22.9 parts of TES, 16.3 parts of VTMS and 220 parts of , .
.:
~e~
- 47 ~
colloidal silica S-l. While the contents of the flask were being stirred, 6 parts of deionized water and 0.1 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C.
After 2 hours, 10 parts of HEMA was added to the mixture. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to à total amount of 160 parts (a solid content of about 50% by weight).
Then, 0.13 part of AIBN was added to 130 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 36 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 6.2 parts of MPTMS and 100 parts of colloidal silica S-l. While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70~C.
After 2 hours, the mixture was cooled to 0C and added :
slowly to a stirred solution which had been prepared by dissolving 5.0 parts of TTIP in 50 parts of isopropyl alcohol and had previously been cooled to 0C. Thereafter, the volatile components were distilled vff at 40C under reduced pressure by means of a rotary evaporator, while MMA
was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 150 parts (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 37 A glass flask fitted with agitating blades was charged with 22.3 parts of MI'ES, 6.2 parts of MPTMS and 300 parts of colloidal silica S-3. While the contents of the flask were being stirred, 0.5 part of 36 wt.~ hydrochloric acid was added thereto and the resulting mixture was heated to 70C.
After 2 hours, the mixture was cooled and 100 parts of HEMA was added thereto. After 100 parts of e-thyl cellosolve was added in order to form an azeotropic mixture with water, . ~ . , -, 2~ , the volatile components were distilled off at 40~C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 172 parts of a mixed solution (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Examples 38-42 Cast plates were obtained in exactly the same manner as described in Example 33, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used were altered as shown in Table 5.
Properties of these cast plates were evaluated and the results thus obtained are shown in Table 5.
.: :
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Table 5 _ _ Radical- Colloidal Silane Total Flexural Flexural Example polymer- silica compound Solid light Haze HDT breaking modulus No. izable con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance ticity2 compound (parts) (parts) (wt.Z) (%) (%) (C) (kglcm2) (kglcm ) Example 33 MMA S-l 100 TES98.8 40 93.6 2.5 185 1,250 4.4x104 MPTMS6.2 _ n 34 HEMA S-2 100 TES 98.836 93.5 3.5 182 1,220 6.0x104 MPTMS 6.2 n 35 S-l 220 MTES 22.9 50 93.4 2.6 198 1,200 7.8x104 HEMA VTMS 16.3 . _ n 36 MMA S-l 100 TES 98.840 92.3 3.8 195 1,200 5.6x104 _ _ n 37 HEMA S-3 300 MTES 22.340 93.5 2.7 145 1,200 5.0x104 MPTMS 6.2 .
_ n 38 MMA S-l 150 TES 36.038 93.5 1.8 190 1,250 5.4x104 MPTMS 4.8 n 39 S-l 200TES 49.1 50 93.3 2.6 205 1,200 7.3x104 . MPTMS 6.5 _ n 40 MMA S-l 100 TES 98.820 93.6 1.7 150 1,200 4.1x104 MPTMS 6.2 . , " 41 MMA S-l 200 TES 49.140 93.0 2.7 170 1,200 5.5x104 VPDMS 5.5 .
n 42 MMA S-l 200 TES49.1 40 92.5 2.7 -158 1,200 5.4x104 HEMA MCTMS 5.1 . l .
_ i Z ~ 3 ` ~3 The abbreviations used in Table 5 are as follows:
VPDMS: p-Vinylphenylmethyldimethoxysilane MCTMS: y-mercaptopropyltrimethoxysilane Thus, the present invention provides composite compositions having high transparency, thermal resistance, rigidity and toughness. These composite compositions are useful in various applications where inorganic glass has heretofore been used, such as windowpanes for houses and vehicles.
carbon-to-carbon double bond, R3 is a hydrogen atom or a hydrocarbon radical oE 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, a and b are whole numbers of O to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, in a dispersion system of colloidal silica.
Detailed Description of the Preferred Embodiments In the composite compositions of the present invention, the silica skeleton of a silica polycondensate derived from colloidal silica and at least one silane compound hydrolyzed and polycondensed on the surfaces thereo~, and a polymer of a radical-polymerizable vinyl compound form a semi-interpenetrating network structure. Accordingly, the composite compositions of the present invention exhibit very high rigidity, toughness and thermal resistance. Moreover, since the present invention permits colloidal silica particles to be incorporated in the silica skeleton and uniformly dispersed therein, they also exhibit very high transparency.
As the radical-polymerizable vinyl compound (A) used in the present invention, there may be employed a variety of well-known radical-polymerizable monomers. Useful radical-polymerizable monomers include, for example, methacrylic esters such as m~thyl methacrylate, ethyl methacrylate, butyl methacrylate and 2-ethylhexyl methacrylate; acrylic esters such as methyl acrylate, ethyl acrylate, butyl ~ '' 7 ~3 acrylate and 2-e~hylhexyl acrylate; unsaturated carboxylic acids such as acrylic acid, methacrylic acid, maleic acid and itaconic acid; acid anhydrides such as malaic anhydride and itaconic anhydride; maleimide derivatives s~ch as N-phenylmaleimide, N-cyclohexylmaleimide and N-t-butylmaleimide; hydroxyl-containing monomers such as 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate and 2-hydroxypropyl methacrylate;
nitrogen-containing monomers such as acrylamide, methacrylamide, acrylonitrile, methacrylonitrila, diacetone acrylamide and dimethylaminoethyl methacrylate; epoxy-containing monomers such as allyl glycidyl ether, glycidyl acrylate and glycidyl methacrylate; styrene monomers such as styrene and ~methylstyrene; and crosslinking agents such as ethylene glycol diacrylate, ethylene glycol dimethacrylate, allyl acrylate, allyl methacrylate, divinylbenzene and trimethylolpropane triacrylate. Among these monomers, methacrylic esters and acrylic esters are preferred. In the radical-polymerizable vinyl compound (A), at least one monomer selected from methacrylic esters and acrylic esters is preferably present in an amount of not less than 50% by weight and more preferably in an amount of not less than 70%
by wei~ht. Especially preferred monomers for use as the radical-polymerizable vinyl compound (A) are methacrylic esters.
Moreover, vinyl compounds having in the molecule at least one group reactive with the silanol groups contained in the silica polycondensate (B) (i.e., at least one functional group selected from the class consisting of hydroxyl, carboxyl, halogenated silyl and alkoxysilyl groups) function to further improve some properties (such as rigidity, toughness and thermal resistance~ of the resulting composite composition. Accordingly, it is preferable that such a vinyl compound be contained as a component of the radical-polymerizable vinyl compound ~A).
Such vinyl compounds having a reactive group in the molecule include, for example, 2-hydroxyethyl (meth)-acrylate, 2-hydroxypropyl (meth)acrylate, (meth)acrylic acid, vinyltrichlorosilane, vinyltrimethoxysilane and y-methacryloyloxypropyltrimethoxysilane. Among these vinyl compounds, 2-hydroxyethyl methacrylate, methacrylic acid, vinyltrichlorosilane, vinyltrimethoxysilane and Y-methacryloyloxypropyltrimethoxysilane are especially preferred.
The silica polycondensate (B) used in the present invention is a product obtained by hydrolysis and polycondensation of at least one silane compound of the general formula SiR1aR2b(oR3)C (I) where Rl and R2 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or , ' Y~
2 ~
carbon-to-carbQn double bond, R3 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, a and b are whole numbers of 0 to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, in a dispersion system of colloidal silica. During this reaction, most of the oR3 groups contained in the silane compound are hydrolyzed, but some oR3 groups, or some oR3 and OH groups, still remain on the ou~er surfaces of the silica polycondensate (B). Therefore, the silica polycondensate (B) dissolves in the radical-polymerizable vinyl compound (A).
The above-described silica polycondensate (B) can be uniformly dispersed in the radical-polymerizahle vinyl compound (A) even at such silica concentrations that the dispersion of colloidal silica alone in ~he radical-polymerizable vinyl compound (A) would cause gelation. That is, the present invention makes it possible to disperse a high concentration of silica uniformly in the resulting composite composition and hence impart desired properties thereto.
As the dispersion of colloidal silica used in the present invention, there may employed a variety of commercial products. The particle diameter of colloidal silica usually ranges ~rom 1 nm to 1 ~m, but no particular limitation is placed on the particle diameter. However, preferred particle diameters are within the range oE 5 to 500 nm. Although no particular limitation is placed on the dispersion medium for colloidal silica, water, alcohols (such as methanol and isopropyl alcohol), cellosolves, dimethylacetamide and the like are usually used. Especially preferred dispersion media are alcohols, cellosolves and water.
Among the silane compounds within the scope of the above general formula (I), silane compounds represented by the following general formulas (II) to (VII) are preferred.
SiR4aR5b(oR6)C (II) SiR4n(0-CH2CH2-o-Co-(R7)C=CH2)4_n (III) CH2=C(R7)Coo(CH2)pSiR8n(0R6)3_n (IV) CH2=CHSiR8n~0R6)3 n (V) HS(CH2)psiR8n(0R6)3-n (VI) and CH2 1 ~ -SiR3n(0R6)3-n (VII) where R4 and R5 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, R7 is a hydrogen atom or a methyl group, R8 is an alkyl group of 1 to 3 carbon atoms or a phenyl group, a and b are whole numbers of O to 3, c is equal to (4-a~b) and represents a whole number of 1 to 4, n i9 a whole number of , ~ J~
O to 2, and p is a whole number of 1 to 6.
The silane compounds represented by the above general formula (II) include, for example, tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, tetrabutoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, dimethyldimethoxysilane, diphenyldimethoxysilane, methylethyldiethoxysilane, methylphenyldimethoxysilane, trimethylethoxysilane, methoxyethyltriethoxysilane, acetoxyethyltriethoxysilane, diethoxyethyldiethoxysilane, tetraacetoxysilane, methyltriacetoxysilane, tetrakis(2-methoxyethoxy)silane and partial hydrolyzates thereof. The silane compounds represented by the above general formula (III) include, for example, tetrakis(acryloyloxyethoxy)silane, tetrakis(methacryloyloxyethoxy)silane, methyltris(acryloyloxyethoxy)silane and methyltris(methacryloyloxyethoxy)silane. Among them, tetrakis(acryloyloxyethoxy)silane and tetrakis(methacryloyloxyethoxy)silane are preferred. These silane compounds can be synthesized, for example, from tetrachlorosilane and 2-hydroxyethyl acrylate or 2-hydroxyethyl methacrylate. The silane compounds represented by the above general formula (IV) include, ~or example, ~-acryloyloxyethyldimethoxymethylsilane, t 2~
~-acryloyloxypropylmethoxydimethylsilane, r-acryloyloxypropyltrimethoxysilane~ ~_ methacryloyloxyethyldimethoxymethylsilane, y-methacryloyloxypropylmethoxydimethylsilane and ~-methacryloyloxypropyltrimethoxysilane. The silane compounds represented by the above general formula (v) include, for example, vinylmethyldimethoxysilane, vinyltrimethoxysilane and vinyltriethoxysilane. The silane compounds represented by the above general formula (VI) include, for example, y-mercaptopropyldimethoxymethylsilane and Y mercaptopropyltrimethoxysilane. The silane compounds represented by the above general formula (VII) include, for example, p-vinylphenylmethyldimethoxysilane and p-vinylphenyltrimethoxysilane.
In the practice of the present invention, the silane compounds represented by the above general formulas (II) to (VII) are preferably used in any of the following five embodiments.
In a first embodiment, at least one silane compound of the above general formula ~II) is used.
In this embodiment, it is preferable to use silane compounds of the abo~e general formula (Il) in which R4, R5 and R6 are hydrocarbon radicals of 1 to 4 carbon atoms.
Where R4, R5 and R6 are hydrocarbon radicals of 4 or less carbon atoms, no significant steric hindrance results.
~ccordingly, the hydrolysis and polycondensation rate 2~ J'~
becomes so high that colloidal silica particles are readily bonded together to form a silica skeleton. Especially preferred silane compounds are tetraalkoxysilanes of the above general formula (II) in which c is equal to 4. In this case, tetraalkoxysilanes are preferably used either alone or in admixture with trialkoxysilanes or dialkoxysilanes to improve stability prior to polymerization.
In a second embodiment, at least one silane compound of the above general formula ~III) is used.
When silane compounds of the general formula (III) are hydrolyzed and polycondensed, some acryloyloxyethoxy or methacryloyloxyethoxy groups are not hydrolyzed and remain in the silica polycondensate (B). During polymerization, these unhydrolyzed acryloyloxyethoxy or methacryloyloxyethoxy groups copolymerize with the radical-polymerizable vinyl compound (A) and chemically combines therewith, thus servîng to reinforce the interface between the polymer of the radical-polymerizable vinyl compound (A) and the silica polycondensate (B).
When the radical-polymerizable vinyl compound (A) is polymerized in the presence of the silica polycondensate (B), some of the unhydrolyzed acryloyloxyethoxy or methacryloyloxyethoxy groups may be el.iminated owin~ to further polycondensation of the silica polycondensate (B).
~t~ ? ~3 Even in thi~ c~se, the eliminated groups copolymerize with the radical-polymeriæable vinyl compound (A) and do not form any volatile component. Accordingly, the finally obtained composite compositions will not suffer foaming, cracking or fracture.
In a third embodiment, at least one silane compound of the above general formula (II) and at least one silane compound of the above general formula (III) are used in combination.
Where these two types of silane compounds are used in combination, the resulting silica polycondensate (B) not only shows the above-described effects produced when each type of silane compound is used alone, but also has resistance to hydrolysis because the silane compound of the general formula (III) is sterically crowded around the silicon atom. Thus, the combined use of these two types of silane compounds is effective in keeping the silica polycondensate (B) stable till the polymerization procedure which will be described later.
In a fourth embodiment, at least one silane compound of any of the above general formulas (IV) to (VII) is used.
Since silane compounds of the general formulas (IV) to (VII) and their hydrolyzates also act as copolymerizable monomers or chain transfer agents during polymerization of the radical-polymerizable vinyl compound (A), they serve to reinforce the interface between the polymer of the radical-' . I
, polymerizable vinyl compound (A) and the silica polycondensate (B) and thereby impart good proper~ies to the finally obtained composite compositions.
In the fifth embodiment, at least one silane compound of the above general formula (II~ and at least one silane compound of any of the above general formulas (IV) to (VII) are used in combination.
Where these two types of silane compounds are used in combination, the silane compound of any of the general formulas (IV) to (VII) is incorporated in the silica skeleton formed from the silane compound of the general formula (II) as described above in connection with the first embodiment. Thus, a stronger bond is produced between the polymer of the radical-polymerizable vinyl compound (A) and the silica polycondensate (B) to impart good properties to the finally obtained composite compositions.
In order to form the silica polycondensate (B) by hydrolysis and polycondensation of the above-defined silane compound in a dispersion system of colloidal silica, the silane compound may be used alone or in combination wi-th a minor amount of a component co-condensable therewith.
Useful components co-condensable with the above-enumerated silane compounds include, for example, metallic alkoxides, organic metallic salts and metallic chelates. Such co-condensable components are preferably used in an amount of O
. .
, `
. 3~3' to 100 parts by weight, more preferably O to 50 parts by weight, per 100 parts by weight of the silane compound.
Specific examples of such co-condensable metallic alkoxides, organic metallic sal~s and metallic chelates include titanium tetraethoxide, titanium tetraisopropoxide, zirconium tetraethoxide, ~irconium tetra-n-butoxide, aluminum triisopropoxide, zinc acetylacetonate, lead acetate and barium oxalate.
In the hydrolysis and polycondensation reaction of the silane compound, water needs to be present in the reaction system. Generally, the proportion of water present in the reaction system exerts no significant lnfluence on the reaction rate. However, if the amount of water is extremely small, the hydrolysis is too slow to form a polycondensate.
In the hydrolysis reaction of the silane compound, an inorganic or organic acid can be used as a catalyst. Useful inorganic acids include, for example, hydrohalogenic acids (such as hydrochloric acid, hydrofluoric acid and hydrobromic acid), sulfuric acid, nitric acid and phosphoric acid. Useful organic acids include, for example, formic acid, acetic acid, oxalic acid, acrylic acid and methacrylic acid.
In the reaction system for hydrolysis of the silane compound, a solvent may be used in order to effect the reaction mildly and uniformly. It is desirable that the solvent allows the reactant (i~e., silane alkoxide), water ~'7 ~ 14 -and the catalyst to be intermixed. Useful solvents include, for example, water; alcohols such as methyl alcohol, e-thyl alcohol and isopropyl alcohol; ketones such as ace~one and methyl isobutyl ketone; and ethers such as t~trahydrofuran and dioxane. For this purpose, the above-described dispersion medium for colloidal silica may be used as it is, or any necessary amount of solvent may be added anew. No particular limi~ation is placed on the amount of solvent used, so long as the reactant can be dissolved homogeneously. However, if the concentration of the reactant is too low, the reaction rate may become unduly slow. The hydrolysis and polycondensation reaction of the silane compound is usually carried out at a temperature ranging from room temperature to about 120C for a period of about 30 minutes to about 24 hours, and preferably at a temperature ranging from room temperature to about the boiling point of the solvent for a period of about 1 to about 10 hours.
In the silica polycondensate (B), no particular limitation is placed on the proportions of colloidal silica and the silane compound of the general formula (I).
However, the silane compound is preferably used in an amount of 0.1 to 2,000 parts by weight, more preferably 1 to 1,000 parts by wei~ht, per 100 parts by weight of the colloidal silica solid component.
.
' ' ' , '~
2~J~
Where the silane compound comprises at least one compound of the general formula (II), the silane compound is preferably used in an amount of 5 to 2,000 parts by weight, more preferably 10 to 1,000 parts by weigh-t, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises at least one compound of the general formula (III), the silane compound is preferably used in an amount of 1 to 2,000 parts by weight, more preferably 5 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises a combination of at least one compound of the general formula (II) and at least one compound of the general formula (III), the compound of the general formula (II) is preferably used in an amount of 5 to 2,000 parts by weight, more preferably 10 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component, and the compound of the general formula (III) is preferably used in an amount of 0.1 to 2,000 parts by weight, more preferably 1 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises at least one compound of any of the general formulas (IV) to (VII), the silane compound is preferably used in an amount of 1 to 2,000 parts by weight, more preferably 5 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
Where the silane compound comprises a combination of at least one compound o the general formula (II) and at least one compound of any of the general formulas (IV) to (VII), the compound of the general formula (II) is preferably used in an amount of 5 to 2,000 parts by weight, more preferably 10 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component, and the compound of any of the general formulas (IV) to (VII) is preferably used in an amount of 0.1 to 2,000 parts by weight, more preferably 1 to 1,000 parts by weight, per 100 parts by weight of the colloidal silica solid component.
The composite compositions of the present invention contain a silica polycondensate (B) formed by hydrolysis and polycondensation of a silane compound in a dispersion system of colloidal silica, and a polymer of a radical-polymerizable vinyl compound (A). The proportions of the radical-polymerizable vinyl compound (~) and the silica polycondensate (B) are preferably chosen so that the components (A) and (B) are present in amounts of 1 to 99% by wei~ht and 99 to 1% by weight, respectively. More preferably, the components (A) and (B) are used in amounts of 10 to 90% by weight and 90 to 10% by weight, respectively. Most preferably, the components (A) and (B~
are used in amounts of 20 to 80~ by wei~ht and 80 to 20% by - ~ - . ; ~ : .
- 17 _ ~,w~
weight, respectively. When the silica polvcondensate (B) is used in an amount of 80 to 20% by weight, the properties desired in the present invention are manifested to a full degree.
The composite compositions of the present invention are preferably produced by mixing the radical-polymerizable vinyl compound (A) and the silica polycondensate (B) in a desired state and polymerizing them concurrently.
Alternatively, they may be produced by partially polymerizing the radical-polymerizable vinyl compound (A) in advance, mixing this partial polymer of the radical-polymerizable vinyl compound (A) and the silica polycondensate, and polymerizing them.
Even when the SiO2 content is 15% by weight or greater, the composite compositions of the present invention have a haze of not greater than 5% as measured at a plate thickness of 3 mm. Electron micrographs reveals that colloidal silica particles are very uniformly dispersed without suffering agglomeration. This means that, in the composite compositions of the present invention, colloidal silica particles are incorporated in the silica skele~on formed by hydrolysis and polycondensation of at least one ~ilane compound and intermingled with the polymer of the radical-polymerizable vinyl compound (A) on a molecular level, thus permitting the achievement of high transparency. In the case of acrylic resins having fine silica particles simply , dispersed therein, their haze as measured at a plate thickness of 3 mm is greater than 20% at SiO2 contents of 15~ by weight or greater, thus showing a marked reduction in transparency.
Although no particular limitation is placed on the method by which the composite compositions of the present invention are produced, it is preferable to produce them according to the conventionally known cast polymeri~ation process. By way of example, the cast polymerization process starts with mixing the radical-polymerizable vinyl compound (A) in the form of a monomer or a partial polymer with the silica polycondensate (B). The solvent and water remaining in this mixture are distilled off to obtain a mixed solution comprising the component (B) dissolved in the component (A).
Then, a casting material is prepared by adding a radical polymerization initiator to the mixed solution. More specifically, the mixing of both components is carried out, for example, by mixing the component (A) directly with a solution of the silica polycondensate (B) in a suitable solvent and then removing the solvent and water associated with the component (B), or by adding the component (A) to a solution of the silica polycondensate (B) while removing therefrom the solvent and water associated with the component (B). Thus, it is important to prepare a mixed solution of both components without causing the component . ''' '.
~ r ~
(B) to separate out as a solid. It is to be understood that the above-described mixed solution can have any viscosity, so long as the component (B) is homogeneously dissolved in the component (A). For example, the mixed solution may have the form of a gel-like material.
The radical polymerization initiators which can be used for this purpose include, for example, azo compounds such as 2,2'-azobisisobutyronitrile, 2,2'-azobis(2,4-dimethylvaleronitrile) and 2,2'-azobis(2,4-dimethyl-4-methoxyvaleronitrile); organic peroxides such as benzoyl peroxide and lauroyl peroxide; and redox polymerization initiators.
This casting material can be cast-polymerized by the cell casting process in which a cell is formed by two surface-treated inorganic glass or metal plates disposed in opposed relationship and ssaled with a gasket at their periphery, and the casting material is poured into the cell and heated; or the continuous casting process in which a casting space is defined by two stainless steel endless belts having one mirror-polished surface and traveling in the same direction at the same speed, and two gaskets disposed along the edges of the belts, and the above-described casting material is continuously poured into the casting space from the upstream side and heated. The polymerization temperature at which the composi~e compositions of the present invention are produced is , ~. , , 2~'~J ~,~? 9 _ 20 --usually within the range of 10 to 150C. However, it is preferable to form a composite composition by efecting polymerization of the radical-polymerizable vinyl compound (A) and further polycondensation of the silica polycondensate (B) concurrently at a temperature above room temperature, i.e., within the r~nge of 40 to 150C.
Furthermore, in any convenient step of the present process, various additives such as colorants, ultraviolet absorbers, thermal stabilizers and mold releasing agents may be incorporated in the composite composition in such amounts as not to impair the effects of the present invention.
The present invention is more specifically explained with reference to the following examples. However, it is to be understood that the present invention is not limited thereto. In these examples, all parts are by weight unless otherwise stated.
Transparency was evaluated by using an integxating sphere type haze meter (SEP-H-SS; manufactured by Japan Precision Optics Co., Ltd.) to measure the total light transmittance and haze of a sample according to ASTM D1003.
Thermal resistance was evaluated by annealing a sample and then measuring its heat distortion temperature (HDT) according to ASTM D648. Strength was evaluated by annealing a sample at 1~0C for 60 hours and then making a bending test of the sample according to ASTM D790 to determine its ,.
~ ' .
flexural breaking strength and flexural modulus of elasticity.
Example 1 A glass flask fitted with agitating blades was charged with 98.8 parts of tetraethoxysilane (hereinafter abbreviated as TES~ and 100 parts of colloidal silica dispersed in isopropyl alcohol so as to have a silica content of 30% by weight (commercially available from Catalyst Chemical Industry Co., Ltd. under the trade name of OSCA~-1432; hereinafter abbreviated as S-1). While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C.
After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while methyl methacrylate (hereinafter abbreviated as MM~) was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixture was concentrated to a tatal amount of 150 parts ~a solid content (i.e., silica polycondensate (B) content) of about 40% by weight).
Then, 0.15 part of 2,2'-azobisisobutyronitrile (hereinafter abbreviated as AIBN) as a polymerization initiator was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it ., was poured into a cell formed by a g~sket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 2 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 4.5 parts of methyltriethoxysilane (hereinafter abbreviated as MTES), 100 parts of colloidal silica S-l and 80 parts of ethanol. While the contents o~
the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amountn of 150 parts (a solid content of about 40%
by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in , .: , Example 1 to obtain a cast pla~eO Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 3 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 4.5 parts of MTES and 100 parts of colloidal silica dispersed in methyl alcohol so as to have a silica content of 30% by weight (commercially available from Catalyst Chemical Industry Co., Ltd. under the trade name of OSCAL-1132; hereinafter abbreviated as S-2). While the contents of the flask were being stirred, 36 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the resultin~ mixture was heated under reflux. After 2 hours, the mixture was cooled and 100 parts of 2-hydroxyethyl methacrylate (hereinafter abbreviated as HEMA~ was added ~hereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 170 parts of a mixed solution (a solid content of about 36% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown - 24 - ~ 3~
in Table 1.
Example 4 A glass flask fitted with agitating blades was charged with 22.3 parts of MTES and 200 parts of colloidal silica S-l. While the contents of the flask were being stirred, 14 parts of deionized water and 0.5 part of 36 wt.%
hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, 10 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 135 parts (a solid content of about 50% by weight).
Then, 0.13 part of AIBN was added to 135 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 5 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 4.5 parts of MTES and 100 parts of colloidal silica S-l. While the contents of the flask were : : ~
, ', ,"~
- : . . . . .
~s ~ 3~1 ~
being stir~ed, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid ware added thereto and the ~emperature was raised to 70C. After 2 hours, ~he mixture was cooled to 0C and added slowly to a s-tirred solution which had been prepared by dissolving 5.0 parts of titanium tetraisopropoxide (hereinafter abbreviated as TTIP) in 50 parts of isopropyl alcohol and had previously been cooled to 0C. Thereafter, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. ~inally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated ko a total amount of 150 parts (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, th~ mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Example 6 A glass flask fitted with agitating blades was charged with 22.3 parts of MTES and 300 parts of colloidal silica dispersed in water so as to have a silica content of 20% by weight (commercially available from Nissan Chemical Industries, Ltd. under the trade name of Snowtex-0;
hereinaftex abbrevia~ed as S-3). While the contents of the flask were being stirred, 0.5 part of 36 wt.~ hydrochloric acid was added thereto and the resulting mixture was heated to 7QC. After 2 hours, the mixture was cooled and 100 parts of HEMA ~as added thereto. After 100 parts of ethyl cellosolve was added in order to form an azeotropic mixture with water, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 170 parts of a mixed solution (a solid content of about 40~ by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, ~he mixed solution was polymerized in exactly the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown ~n Table 1.
Examples 7-9 Cast plates were obtained in exactly the same manner as described in Example 1, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used were altered as shown in Table 1.
Properties of these cast plates wexe evaluated and the results thus obtained are shown in ~able 1.
Comparative Exam~le 1 ? ~
0.15 part of AIBN was dissolved in 150 parts of MMA.
This mixture was polymerized in the same manner as described in Example 1 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 1.
Comparative Example 2 An at~empt was made to prepare a solution having a solid content of 30% by weight from colloidal silica and MMA. Specifically, the volatile components were distilled off from 100 parts of colloidal silica S-l at 40C under reduced pressure by means of a rotary evaporator, while MMA
was added at the same rate as the volatile components were distilled off. However, before khe solvent was completely replaced by MMA, the solution showed an abrupt increase in viscosity and formed a gel, which made it impossible to subject the solution to the polymerization procedure.
', ' z~
Table 1 Radical- Colloidal Silane Total ~ Flexural Flexural Example polymer- silica compound Solid light Haze HDT breaking modulus No. izable ~ con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance ticit2 compound (parts) (parts) (wt.Z) (Z) (%) (C) (kg/om2) (kglcm ) Example 1 MMA S-l 100 TES98.8 4o----- 93.6 2.7 185 1,200 4.8x104 a 2 MMA S-l 100 TES98.8 40 93.3 2.6 164 1,230 4.5x104 MTES4.5 _ . . ~ _ a 3 HEMA S-2 100 TES 98.8 36 92.6 3.6 159 1,240 6.2x104 MTES 4.5 _ n 4 MMA S-l 200 MTES 22.3 50 92.5 2.9 148 1,200 5.7x104 HEMA
.
MMA S-l 100 TES98.8 40 92.2 3.8 160 1,200 5.8x104 . _ MTES4.5 .
n 6 HEMA S-3 300 MTES - 22.3 40 92.4 3.6 145 1,200 5.2x104 _ _ MMA S-l 150 TES36.0 38 93.3 2.5 166 1,230 5.5x104 MTES, 3.5 ~
_ 8 MMA S-l 200 TES49.1 50 92.3 2.6 202 . 1,200 7.3x104 MTES4.7 n g MMA S-l 100 TES98.8 20 93.6 1.7 150 1,200 4.1x104 _ _ _ _ Comparative Example 1 _ _ _ _ _ 92.1 1.3 100 1,200 3.5x104 _ Synthesis Example While 208 parts of HEMA was being stirred at room temperature, 68 parts of tetrachlorosilane was added dropwise thereto over a period of 4 hours. After completion of the addition, the stirring was continued for 0.5 hour and the temperature was then raised to 50C. After an hour, the volatile components were completely removed by means of a rotary evaporator to obtain tetrakis(methacryloyloxyethoxy)-silane ~hereinafter abbreviated as TMES).
Moreover, tetrakis(acryloyloxyethoxy)silane thereinafter abbreviated as TAES) was obtained in the same manner as described above, except that 208 parts of HEMA was replaced by 186 parts of 2-hydroxyethyl acrylate.
Example 10 A glass flask fitted with agitating blades was charged with 32.6 parts of the TMES prepared in Synthesis Example and 240 parts of colloidal silica S-1. While the contents of the flask were being stirred, 8.6 parts of deionized water and 0.1 part of 36 wt.~ hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the volatile components were distilled off at 40C
under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution , , .
, was concentrated to a total amount of 150 parts (a solid content of about 50~ by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell formed by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate.
Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
Example 11 A glass flask fitted with agitating blades was charged with 32.6 parts of TMES and 240 parts of colloidal silica S-l. While the contents of the flask were being stirred, 4.3 parts of deionized water and 0.1 part of 36 wt.~
hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the mixture was cooled and 75 parts of HEMA was added thereto. Then, the volatile components were distiIled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. I'hus, there was obtained 150 parts of a mixed solution (a solid content of about 50~ by weight).
?
~ 31 -Thenr 0.15 part of AIBN was added to lS0 parts of the above mixed solution. Thereaftex, the mixed solu~ion was polymerized in exactly the same manner as described in Example 10 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
Example 12 A glass flask fitted with agitating blades was charged with 32.6 parts of TMES and 240 par~s of colloidal silica S-2. While the contents of the flask were being stirred, 4.3 parts of deionized water and 0.1 part of 36 wt.%
hydrochloric acid were added thereto and the resulting mixture was heated under reflux. After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finallyr the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 150 parts (a solid content of about 50% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 10 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
J~ f~
Example 13 A glass flask fitted with agitating blades was charged with 27.2 parts of TMES and 300 parts of colloidal silica S-3. While the contents of the flask were being stirred, 0.5 part of 36 wt.% hydrochloric acid was added thereto and the resulting mixture was heated to 70C. After 2 hours, the mixture was cooled and 95 parts of HEMA was added thereto. After 100 parts of ethyl cellosolve was added in order to form an azeotropic mixture with water, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 157 parts of a mixed solution (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exac~ly the same manner as described in Example 10 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 2.
Examples 14-16 Cast plates were obtained in exactly the same manner as described in Example 10, except that the types and amounts of radical-polymeriæable vinyl compound, colloidal silica and silane compound used and the solid content of the mixed ~t~?,~
solution were altered as shown in Table 2. Properties of these cast plates were evaluated and the results thus obtained are shown in Table 2.
- 3~ -Table 2 Radical- ColloidalSilane Total Flexural Flexural Example polymer- silicacompoundSolid light Haze HDT breaking modulus No. izable con- trans- strength of elas_ vinyl Type Amount Type Amount tent mittance 2 ticity~
compound(parts) (parts) (wt.%) (%) (%) (C) (kg~cm ) (kg/cm ) _ _ Example 10 MMA S-l 240 TMES 32.6 50 93.2 1.6 151 1,250 7.7x104 n11 HEMA S-l 240 TMES 32.6 50 93.3 2.5 146 1,250 7.6x104 . _ ~
n12 MMAS-2 240 TMES 32.6 5092.9 1.7 152 1,200 7.6x104 . __ n13 HEMA S-3 300 TMES27.2 4092.6 2.7 144 1,200 6.8x104 n14 MMAS-l 240 TAES 29.3 5093.2 1.6 143 1,250 6.3x104 _ "15 MMAS-l 100 TMES 13.0 2093.0 1.6 135 1,230 5.0x104 ~ _ n16 MMA S-l 240 ,~MES.65.2 4093.1 1.5 149 1,250 6.5x104 _ _ :; . ' ., - 35 - 2~ 9 ExamPle 17 A glass flask ~itted with agitatin~ blades was charged with 41.6 parts of TES, 27 . 2 parts of TMES and 200 parts of colloidal silica S-l. While the contents of the flask were being stirred, 9 parts of deionized water and 0.2 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised -to 70C.
After 2 hours, the volatile components ~ere distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount o~ 150 parts ~a solid conte~t of about 50% by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mi~ed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell forrned by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 5 hours and then at 130C for 2 hours to obtain a cast plate.
Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 18 A glass flask fitted with agitating blades was charged with 41.6 paxts of TES, 27.2 parts of TMES and 200 parts of colloidal silica S-2. While the contents of the flask were being stirred, 36 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the resulting mixture was heated under reflux.
After 2 hours, the mixture was cooled and 75 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 150 parts of a mixed solution (a solid content of about 50% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 19 A glass flask fitted with agitating hlades was charged with 26.7 parts of ~TES, 27.2 parts of TMES and 200 parts of colloidal silica S-l. While the contents of the flask were being stirred, 14 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and ~he temperature was raised to 70C.
- , ,:~
- 37 _ After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resultin~
mixed solution was concentrated to a total amount of 144 parts (a solid content of about 50~ by weight).
Then, 0.13 part of AIBN was added to 135 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 20 A glass flask fitted with agitating blades was charged with 41.6 parts of TES, 27.2 parts of TMES and 200 parts of colloidal silica S-1. While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C.
After 2 hours, the mixture was cooled to 0C and added slowly to a stirred solution which had been prepared by dissolving 5.0 parts of TTIP in 50 parts of isopropyl alcohol and had previously been cooled to 0C. Thereafter, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA
,.
:
was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount o~ 190 parts (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
Example 21 A glass flask fitted with agitating blades was charged with 26.7 parts of MTES, 27.2 parts of TMES and 300 parts of colloidal silica S-3. While the contents of the flask were being stirred, 0.5 part of 36 wt.~ hydrochloric acid was added thereto and the resulting mixture was heated to 70C.
After 2 hours, the mixture was cooled and 100 parts of HEMA was added thereto. After 100 parts of ethyl cellosolve was added in order to form an azeotropic mixture with water, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off ~y means of a vacuum pump. Thus, there was obtained 180 parts of a mixed solution (a solid content of about 40% by weight).
~, ~ ' J~?~
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 17 to obtain a cas~ plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 3.
ExamPles 22-24 Cast plates were obtained in exactly the same manner as described in Example 17, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used were altered as shown in Table 3.
Properties of these cast plates were evaluated and the results thus obtained are shown in Table 3.
2~
Table 3 Radical- ColloidalSilane Total Flexural Flexural Example polymer- silicacompound Solid light Haze HDT breaking modulus No. izable con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance tiCitY2 compound (parts) (parts) (wt.Z) (%) (%) (C) (kg/cm2) (kglcm ) _ _ _ Example 17 MMA S-1 200 TES 41.6 50 92.8 2.7 153 1,210 7.3x104 TMES 27.2 . . _ _ n 18 HEMA S-2 200 TES 41.6 50 92.6 2.8 156 1,220 7.2x104 TMES 27.2 _ n 19 ~MA S-l 200 MTES 26.7 50 92.5 2.8 142 1,200 6.6x104 TMES 27.2 i _ _ _ n 20 MMA S-l 200 TES 41.6 40 91.8 2.9 155 1,210 6.7x104 TMES 27.Z _ ~
n 21 HEMA S-3 300MTES 26.7 40 92.6 3.2 141 1,200 6.4x104 TMES 27.2 _ _ n 22 MMA S-l 200 TES 41.6 50 92.6 2.6 136 1,250 5.9x104 _ TAES 24.4 _ n 23 MMA S-l 100 TES 20.8 20 93.0 1.7 134 1,230 5.1x104 . TMES 18.6 __ _ n , 24 MMA S-l 240 TES 10.4 55 92.8 - 2.6 176 1,210 7.9x104 TMES 27.2 _ ,, ~
. .
' . ' ~.
3 ,~ ~
~, ~ 41 -Example 25 A glass flask fitted with agitating blades was charged with 29.8 parts of ~methacryloyloxypropyltrimethoxysilane (hereinafter abbreviated as MPTMS) and 240 parts of colloidal silica S-l. While the contents of the flask were being stirred, 6.5 parts of deionized water and 0.1 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off.
Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 158 parts (a solid content of about 50% by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell formed by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate.
Properties of this cast plate were evaluated and the results thus obtained are shown in Table 4.
Example 26 A glass flask fitted with agitating blades was charged 3 ~ ~
with 17.8 parts of vinyltrimethoxysilane (hereinafter abbreviated as VTMS) and 240 parts of colloidal silica S-1.
While the contents of the flask were being stirred, 6.5 parts of deionized water and 0.1 part of 36 wt.%
hydrochloric acid were added thereto and ~he resulting mixture was heated to 70C. After 2 hours, the mixture was cooled and 10 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressuxe by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 158 parts (a solid content of about 50% by weight)~
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 25 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 4.
Example 27 A glass flask fitted with agitating blades was charged with 29.8 parts of MPTMS and 240 parts of colloidal silica S-2. While the contents of the flask were being stirred, 6.5 parts of deionized water and 0.1 part of 36 wt.%
:
,'~' ' ' ' , .
.
- ~3 -hydrochloric acid were added thereto and the temperature was raised to 70C. After 2 hours, the mixture was cooled and 75 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means o~ a vacuum pump. Thus, there was obtained 158 parts of a mixed solution (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 25 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 4.
Examples 28-32 Cast plates were obtained in exactly the same manner as described in Example 25, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used and the solid content of the mixed solution were altered as shown in Table 4. Properties of these cast plates were evaluated and the results thus obtained are shown in Table 4.
2~ l ~o~
Table 4 Radical- ColloidalSilane Total Flexural Flexural Example polymer- silicacompoundSolid light Haze HDT breaking modulus No. izable con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance 2 ticitY2 compound (parts) (parts) (wt.%) (Z) (%) (C) (kg/cm ) (kglcm ) Example 25 ~MA S-l 240 MPTMS 29.8 50 93.5 2.6 192 1,220 8.7x104 26 MMA S-l 240 VTMS17.8 50 93.4 2.5 186 1,220 8.6x104 HEMA
n 27 HEMA S-2 240 MPTMS 29.8 50 93.1 2.7 185 1,200 8.4x104 n 28 MMA S-l 240 MCTMS 23.6 50 93.0 2.7 190 1,200 8.3x104 n 29 MMA S-l 240 MPDMS 27.8 50 93.1 2.7 167 1,250 7.8x104 _ n 30 MMA S-l 100 VTMS3.5 20 93.4 1.8 165 1,250 5.0x104 a 31 MMA S-l 240 VTUS35.5 40 93.5 2.5 17a 1,250 6.9x104 n 32 MMA S-l 240 VPDMS 26.4 40 93.0 2.5 162 1,200 6.5xlo4 The abbreviations used in Table 4 are as follows:
MCTMS: r-mercaptopropyltrimethoxysilane MPDMS: y~Methacryloyloxypropyldimethoxymethylsilane VPDMS: p-Vinylphenylmethyldimethoxysilane Example 33 A glass flasX fitted with agitating blades was charged with 98.8 parts of TES, 6.2 parts of MPTMS, 100 parts of colloidal silica S-l and 80 parts of ethanol. While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C
After 2 hours, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by ~MA and the resulting mixed solution was concentrated to a total amount of 150 parts (a solid content of about 40~ by weight).
Then, 0.15 part of AIBN was added to and dissolved in 150 parts of the above mixed solution. After the mixed solution was exposed to reduced pressure in order to remove any dissolved air, it was poured into a cell formed by a gasket and two stainless steel plates and adjusted previously so as to have a thickness of 3 mm. Subsequently, the mixed solution was polymerized at 80C for 2 hours and then at 130C for 2 hours to obtain a cast plate.
.
~ f ~ 3"~3 Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 34 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 6.2 parts of MPTMS and 100 parts of colloidal silica S-2. While the contents of the flask were being stirred, 36 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the resulting mixture was heated under reflux.
After 2 hours, the mixture was cooled and 100 parts of HEMA was added thereto. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 170 parts of a mixed solution (a solid content of about 36% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 35 A glass flask fitted with agitatin~ blades was charged with 22.9 parts of TES, 16.3 parts of VTMS and 220 parts of , .
.:
~e~
- 47 ~
colloidal silica S-l. While the contents of the flask were being stirred, 6 parts of deionized water and 0.1 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70C.
After 2 hours, 10 parts of HEMA was added to the mixture. Then, the volatile components were distilled off at 40C under reduced pressure by means of a rotary evaporator, while MMA was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to à total amount of 160 parts (a solid content of about 50% by weight).
Then, 0.13 part of AIBN was added to 130 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 36 A glass flask fitted with agitating blades was charged with 98.8 parts of TES, 6.2 parts of MPTMS and 100 parts of colloidal silica S-l. While the contents of the flask were being stirred, 18 parts of deionized water and 0.5 part of 36 wt.% hydrochloric acid were added thereto and the temperature was raised to 70~C.
After 2 hours, the mixture was cooled to 0C and added :
slowly to a stirred solution which had been prepared by dissolving 5.0 parts of TTIP in 50 parts of isopropyl alcohol and had previously been cooled to 0C. Thereafter, the volatile components were distilled vff at 40C under reduced pressure by means of a rotary evaporator, while MMA
was added at the same rate as the volatile components were distilled off. Finally, the solvent was completely replaced by MMA and the resulting mixed solution was concentrated to a total amount of 150 parts (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Example 37 A glass flask fitted with agitating blades was charged with 22.3 parts of MI'ES, 6.2 parts of MPTMS and 300 parts of colloidal silica S-3. While the contents of the flask were being stirred, 0.5 part of 36 wt.~ hydrochloric acid was added thereto and the resulting mixture was heated to 70C.
After 2 hours, the mixture was cooled and 100 parts of HEMA was added thereto. After 100 parts of e-thyl cellosolve was added in order to form an azeotropic mixture with water, . ~ . , -, 2~ , the volatile components were distilled off at 40~C under reduced pressure by means of a rotary evaporator and, furthermore, completely distilled off by means of a vacuum pump. Thus, there was obtained 172 parts of a mixed solution (a solid content of about 40% by weight).
Then, 0.15 part of AIBN was added to 150 parts of the above mixed solution. Thereafter, the mixed solution was polymerized in exactly the same manner as described in Example 33 to obtain a cast plate. Properties of this cast plate were evaluated and the results thus obtained are shown in Table 5.
Examples 38-42 Cast plates were obtained in exactly the same manner as described in Example 33, except that the types and amounts of radical-polymerizable vinyl compound, colloidal silica and silane compound used were altered as shown in Table 5.
Properties of these cast plates were evaluated and the results thus obtained are shown in Table 5.
.: :
:.
, `: ' , .
~9 1 ~
fCi"~ S ~
Table 5 _ _ Radical- Colloidal Silane Total Flexural Flexural Example polymer- silica compound Solid light Haze HDT breaking modulus No. izable con- trans- strength of elas-vinyl Type Amount Type Amount tent mittance ticity2 compound (parts) (parts) (wt.Z) (%) (%) (C) (kglcm2) (kglcm ) Example 33 MMA S-l 100 TES98.8 40 93.6 2.5 185 1,250 4.4x104 MPTMS6.2 _ n 34 HEMA S-2 100 TES 98.836 93.5 3.5 182 1,220 6.0x104 MPTMS 6.2 n 35 S-l 220 MTES 22.9 50 93.4 2.6 198 1,200 7.8x104 HEMA VTMS 16.3 . _ n 36 MMA S-l 100 TES 98.840 92.3 3.8 195 1,200 5.6x104 _ _ n 37 HEMA S-3 300 MTES 22.340 93.5 2.7 145 1,200 5.0x104 MPTMS 6.2 .
_ n 38 MMA S-l 150 TES 36.038 93.5 1.8 190 1,250 5.4x104 MPTMS 4.8 n 39 S-l 200TES 49.1 50 93.3 2.6 205 1,200 7.3x104 . MPTMS 6.5 _ n 40 MMA S-l 100 TES 98.820 93.6 1.7 150 1,200 4.1x104 MPTMS 6.2 . , " 41 MMA S-l 200 TES 49.140 93.0 2.7 170 1,200 5.5x104 VPDMS 5.5 .
n 42 MMA S-l 200 TES49.1 40 92.5 2.7 -158 1,200 5.4x104 HEMA MCTMS 5.1 . l .
_ i Z ~ 3 ` ~3 The abbreviations used in Table 5 are as follows:
VPDMS: p-Vinylphenylmethyldimethoxysilane MCTMS: y-mercaptopropyltrimethoxysilane Thus, the present invention provides composite compositions having high transparency, thermal resistance, rigidity and toughness. These composite compositions are useful in various applications where inorganic glass has heretofore been used, such as windowpanes for houses and vehicles.
Claims (18)
1. A composite composition obtained by polymerizing a radical-polymerizable vinyl compound (A) in the presence of a silica polycondensate formed by hydrolysis and polycondensation of at least one silane compound of the general formula SiR1aR2b(OR3)C (I) where R1 and R2 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, R3 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, a and b are whole numbers of 0 to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, in a dispersion system of colloidal silica.
2. A composite composition as claimed in claim 1 which consists essentially of 1 to 99% by weight of the radical-polymerizable vinyl compound (A) and 99 to 1% by weight of the silica polycondensate (B).
3. A composite composition as claimed in claim 2 which consists essentially of 10 to 90% by weight of the radical-polymerizable vinyl compound (A) and 90 to 10% by weight of the silica polycondensate (B).
4. A composite composition as claimed in claim 2 which consists essentially of 20 to 80% by weight of the radical-polymerizable vinyl compound (A) and 80 to 20% by weight of the silica polycondensate (B).
5. A composite composition as claimed in claim 1 wherein the silica polycondensate (B) is formed by using 0.1 to 2,000 parts by weight of the silane compound per 100 parts by weight of the colloidal silica solid component.
6. A composite composition as claimed in claim 5 in which the silica polycondensate (B) is formed by using 1 to 1,000 parts by weight of the silane compound per 100 parts by weight of the colloidal silica solid component.
7. A composite composition as claimed in claim 1 wherein the radical-polymerizable vinyl compound (A) is a methacrylic ester.
8. A composite composition as claimed in claim 1 which has a SiO2 content of not less than 15% by weight and a haze of not greater than 5% as measured at a plate thickness of 3 mm.
9. A composite composition as claimed in claim 1 wherein the silane compound comprises at least one compound of the general formula SiR4aR5b(OR6)c (II) where R4 and R5 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, a and b are whole numbers of 0 to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4.
10. A composite composition as claimed in claim 1 wherein the silane compound comprises at least one compound of the general formula SiR4n(O-CH2CH2-O-CO-(R7)C=CH2)4-n (III) where R4 is a hydrocarbon radical of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R7 is a hydrogen atom or a methyl group, and n is a whole number of 0 to 2.
11. A composite composition as claimed in claim 1 wherein the silane compound comprises a mixture composed of at least one compound of the general formula SiR4aR5b(OR6)C (II) where R4 and R5 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, a and b are whole numbers of 0 to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, and at least one compound of the general formula SiR4n(O-CH2CH2-O-CO-(R7)C=CH2)4-n (III) where R4 is a hydrocarbon radical of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R7 is a hydrogen atom or a methyl group, and n is a whole number of 0 to 2.
12. A composite composition as claimed in claim 1 wherein the silane compound comprises at least one compound of any of the general formulas CH2=C(R7)COO(CH2)pSiR8n(OR6)3-n (IV) CH2=CHSiR8n(OR6)3-n (v) HS(CH2)pSiR8n(OR6)3-n (VI) and (VII) where R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, R7 is a hydrogen atom or a methyl group, R8 is an alkyl group of 1 to 3 carbon atoms or a phenyl group, n is a whole number of 0 to 2, and p is a whole number of 1 to 6.
13. A composite composition as claimed in claim 1 wherein the silane compound comprises a mixture composed of at least one compound of the general formula SiR4aR5b(OR6)C (II) where R4 and R5 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage or ester linkage, R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, a and b are whole numbers of O to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, and at least one compound of any of the general formulas CH2=C(R7)COO(CH2)pSiR8n(OR6)3-n (IV) CH2=CHSiR8n(OR6)3-n (V) HS(CH2)pSiR8n(OR6)3-n (VI) and (VII) where R6 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms, R7 is a hydrogen atom or a methyl group, R8 is an alkyl group of 1 to 3 carbon atoms or a phenyl group, n is a whole number of O to 2, and p is a whole number of 1 to 6.
14. A process for producing composite compositions which comprises the steps of providing a silica polycondensate (B) formed by hydrolysis and polycondensation of at least one silane compound of the general formula SiR1aR2b(OR3)c (I) where R1 and R2 are hydrocarbon radicals of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, R3 is a hydrogen atom or a hydrocarbon radical of 1 to 10 carbon atoms which may contain an ether linkage, ester linkage or carbon-to-carbon double bond, a and b are whole numbers of O to 3, and c is equal to (4-a-b) and represents a whole number of 1 to 4, in a dispersion system of colloidal silica; preparing a mixed solution by dissolving the silica polycondensate (B) in a radical-polymerizable vinyl compound (A) or a partial polymer thereof; and effecting radical polymerization of the mixed solution.
15. A process for producing composite compositions as claimed in claim 14 wherein the radical polymerization of the mixed solution and the further polycondensation of the silica polycondensate (B) in the mixed solution are effected concurrently.
16. A process for producing composite compositions as claimed in claim 14 wherein the radical polymerization of the mixed solution and the further polycondensation of the silica polycondensate (B) are effected at a temperature of 40° to 150°C.
17. A process for producing composite compositions as claimed in claim 14 wherein the mixed solution is prepared by dissolving the silica polycondensate (B) in a solvent, mixing the resulting solution with the component (A), and then distilling off the solvent and water associated with the component (B).
18. A process for producing composite compositions as claimed in claim 14 wherein the mixed solution is prepared by dissolving the silica polycondensate (B) in a solvent to form a solution and adding the component (A) to the solution while distilling off the solvent and water therefrom.
Applications Claiming Priority (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP243398/1991 | 1991-09-24 | ||
JP243402/1991 | 1991-09-24 | ||
JP24340391 | 1991-09-24 | ||
JP243403/1991 | 1991-09-24 | ||
JP243397/1991 | 1991-09-24 | ||
JP24339891 | 1991-09-24 | ||
JP243401/1991 | 1991-09-24 | ||
JP24340291 | 1991-09-24 | ||
JP24340191 | 1991-09-24 | ||
JP24339791 | 1991-09-24 |
Publications (1)
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CA2078949A1 true CA2078949A1 (en) | 1993-03-25 |
Family
ID=27530084
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA002078949A Abandoned CA2078949A1 (en) | 1991-09-24 | 1992-09-23 | Composite composition having high transparency and process for producing same |
Country Status (4)
Country | Link |
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US (1) | US5385988A (en) |
EP (1) | EP0534753B1 (en) |
CA (1) | CA2078949A1 (en) |
DE (1) | DE69216030T2 (en) |
Families Citing this family (23)
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US5683501A (en) * | 1993-11-09 | 1997-11-04 | Nippon Shokubai Co., Ltd. | Compound fine particles and composition for forming film |
US5503932A (en) * | 1993-11-17 | 1996-04-02 | Nippon Shokubai Co., Ltd. | Organic-inorganic composite particles and production process therefor |
DE4344309A1 (en) * | 1993-12-23 | 1995-06-29 | Wacker Chemie Gmbh | Soluble organopolysiloxane radical macroinitiators for graft copolymerization |
JP3386906B2 (en) * | 1994-01-18 | 2003-03-17 | 大日本印刷株式会社 | Coating composition, manufacturing method thereof, coating film forming method and coating film |
US5670257A (en) * | 1994-11-15 | 1997-09-23 | Nippon Shokubai Co., Ltd. | Organic-inorganic composite particles and production process therefor |
DE69633916T2 (en) * | 1995-04-25 | 2005-09-22 | Mitsubishi Rayon Co., Ltd. | COMPOSITE MATERIALS AND MOLDED PARTS MANUFACTURED THEREFROM |
DE19519446A1 (en) * | 1995-05-26 | 1996-11-28 | Wacker Chemie Gmbh | Monodisperse soluble organopolysiloxane particles |
FR2755138B1 (en) * | 1996-10-24 | 1999-01-22 | Truyol Albert | PROCESS FOR THE PREPARATION OF A HYBRID SOL FOR USE IN THE INACTIVATION OF ASBESTOS |
EP0956273A1 (en) * | 1996-12-13 | 1999-11-17 | Corning Incorporated | Optically transmissive material and bond |
US5979984A (en) * | 1997-10-24 | 1999-11-09 | Steelcase Development Inc. | Synchrotilt chair with forwardly movable seat |
DE19909894A1 (en) | 1999-03-06 | 2000-09-07 | Basf Coatings Ag | Sol-gel coating for single-layer or multi-layer coatings |
DE19940858A1 (en) | 1999-08-27 | 2001-03-01 | Basf Coatings Ag | Sol-gel coating for single-layer or multi-layer coatings |
GB9923747D0 (en) * | 1999-10-07 | 1999-12-08 | Welding Inst | Composite materials,their production and uses |
DE10200929A1 (en) * | 2002-01-12 | 2003-07-31 | Basf Coatings Ag | Polysiloxane brine, process for their preparation and their use |
US6991852B2 (en) * | 2002-03-13 | 2006-01-31 | Regents Of The University Of Minnesota | Silica-based materials and methods |
DE10212458A1 (en) * | 2002-03-20 | 2003-10-02 | Roehm Gmbh | Hail resistant composite acrylic and process for its production |
DE10214436A1 (en) * | 2002-03-27 | 2003-10-23 | Blanco Gmbh & Co Kg | Casting compound and molded plastic body made therefrom |
US20060076296A1 (en) * | 2004-10-13 | 2006-04-13 | Wu Chen | Novel stationary phases for use in high-performance liquid chromatography |
US20050242038A1 (en) * | 2004-04-30 | 2005-11-03 | Wu Chen | Novel stationary phases for use in high-performance liquid chromatography |
US20110098411A1 (en) * | 2008-07-03 | 2011-04-28 | Showa Denko K.K. | Curable composition and cured product thereof |
CN101747478B (en) * | 2008-12-17 | 2012-02-01 | 中国科学院大连化学物理研究所 | 'One-pot' preparation of organic-inorganic hybridization porous monolithic material |
EP2813521A4 (en) | 2012-02-10 | 2016-03-02 | Showa Denko Kk | Curable composition and application therefor |
CN108299493B (en) * | 2016-07-06 | 2021-01-12 | 浙江佑泰新材料科技有限公司 | Silicon-containing acrylate monomer and preparation method and application thereof |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
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CA600976A (en) * | 1960-07-05 | L. Berry Kenneth | Siliceous material coated with chemically bonded addition-type polymers of ethylenically-unsaturated compounds | |
US3324074A (en) * | 1965-01-06 | 1967-06-06 | Monsanto Co | Methacrylate polymers with fillers and coupling agents |
FR2098467A5 (en) * | 1969-11-06 | 1972-03-10 | Eternit | |
JPS535708B2 (en) * | 1972-02-24 | 1978-03-01 | ||
GB1456865A (en) * | 1973-12-14 | 1976-12-01 | Pye Ltd | Method of bonding copolymers |
EP0069133B2 (en) * | 1981-01-15 | 1990-04-11 | Battelle Development Corporation | Photo setting composition for coating substrates with an abrasion-resistant transparent or translucent film |
SU1214685A1 (en) * | 1984-05-04 | 1986-02-28 | Предприятие П/Я М-5927 | Method of producing modified silicon-containing filler |
JPS62256874A (en) * | 1986-05-01 | 1987-11-09 | Toshiba Silicone Co Ltd | Production of ultraviolet curable composition |
JP2537877B2 (en) * | 1987-06-12 | 1996-09-25 | 株式会社クラレ | Method for producing methacrylic resin molded article |
CA2010689A1 (en) * | 1989-02-27 | 1990-08-27 | Nobuhiro Mukai | Process for producing powders |
US5218014A (en) * | 1989-12-18 | 1993-06-08 | Toshiba Silicone Co., Ltd. | Thermoplastic resin and process for reducing the same |
-
1992
- 1992-09-22 US US07/948,421 patent/US5385988A/en not_active Expired - Lifetime
- 1992-09-23 CA CA002078949A patent/CA2078949A1/en not_active Abandoned
- 1992-09-24 EP EP92308703A patent/EP0534753B1/en not_active Expired - Lifetime
- 1992-09-24 DE DE69216030T patent/DE69216030T2/en not_active Expired - Lifetime
Also Published As
Publication number | Publication date |
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EP0534753A1 (en) | 1993-03-31 |
US5385988A (en) | 1995-01-31 |
EP0534753B1 (en) | 1996-12-18 |
DE69216030T2 (en) | 1997-04-10 |
DE69216030D1 (en) | 1997-01-30 |
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